Surgical end effectors and anvils

ABSTRACT

A surgical end effector is disclosed. The end effector can include an anvil comprising a planar surface, wherein a plurality of forming pockets is defined in the planar surface. The forming pockets can include a first forming pocket comprising a first depth and a second forming pocket comprising a second depth, wherein the second depth is different than the first depth. The end effector can also include a staple cartridge comprising a stepped deck, a first driver aligned with the first pocket and movable a first distance between an unfired position and a fired position, and a second driver aligned with the second pocket and movable a second distance between an unfired position and a fired position, wherein the second distance is different than the first distance.

BACKGROUND

The present invention relates to surgical instruments and, in variousarrangements, to surgical stapling and cutting instruments and staplecartridges for use therewith that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together withadvantages thereof, may be understood in accordance with the followingdescription taken in conjunction with the accompanying drawings asfollows:

FIG. 1 is a side elevational view of a surgical system comprising ahandle assembly and multiple interchangeable surgical tool assembliesthat may be used therewith;

FIG. 2 is a perspective view of one of the interchangeable surgical toolassemblies of FIG. 1 operably coupled to the handle assembly of FIG. 1;

FIG. 3 is an exploded assembly view of portions of the handle assemblyand interchangeable surgical tool assembly of FIGS. 1 and 2;

FIG. 4 is a perspective view of another one of the interchangeablesurgical tool assemblies depicted in FIG. 1;

FIG. 5 is a partial cross-sectional perspective view of theinterchangeable surgical tool assembly of FIG. 4;

FIG. 6 is another partial cross-sectional view of a portion of theinterchangeable surgical tool assembly of FIGS. 4 and 5;

FIG. 7 is an exploded assembly view of a portion of the interchangeablesurgical tool assembly of FIGS. 4-6;

FIG. 7A is an enlarged top view of a portion of an elastic spineassembly of the interchangeable surgical tool assembly of FIG. 7;

FIG. 8 is an exploded assembly view of a portion of the interchangeablesurgical tool assembly of FIGS. 4-7;

FIG. 9 is a cross-sectional perspective view of a surgical end effectorportion of the interchangeable surgical tool assembly of FIGS. 4-8;

FIG. 10 is an exploded assembly view of the surgical end effectorportion of the interchangeable surgical tool assembly depicted in FIG.9;

FIG. 11 is a perspective view, a side elevational view and a frontelevational view of a firing member that may be employed in theinterchangeable surgical tool assembly of FIGS. 4-10;

FIG. 12 is a perspective view of an anvil that may be employed in theinterchangeable surgical tool assembly of FIGS. 4-11;

FIG. 13 is a cross-sectional side elevational view of the anvil of FIG.12;

FIG. 14 is a bottom view of the anvil of FIGS. 12 and 13;

FIG. 15 is a cross-sectional side elevational view of a portion of asurgical end effector and shaft portion of the interchangeable surgicaltool assembly of FIG. 4 with an unspent surgical staple cartridgeproperly seated within an elongate channel of the surgical end effector;

FIG. 16 is a cross-sectional side elevational view of the surgical endeffector and shaft portion of FIG. 15 after the surgical staplecartridge has been fired during a staple firing stroke and a firingmember being retracted to a starting position after the staple firingstroke;

FIG. 17 is another cross-sectional side elevational view of the surgicalend effector and shaft portion of FIG. 16 after the firing member hasbeen fully retracted back to its starting position;

FIG. 18 is a top cross-sectional view of the surgical end effector andshaft portion depicted in FIG. 15 with the unspent surgical staplecartridge properly seated with the elongate channel of the surgical endeffector;

FIG. 19 is another top cross-sectional view of the surgical end effectorof FIG. 15 with a fired surgical staple cartridge mounted thereinillustrating the firing member retained in a locked position;

FIG. 20 is a partial cross-sectional view of portions of the anvil andelongate channel of the interchangeable tool assembly of FIG. 4;

FIG. 21 is an exploded side elevational view of portions of the anviland elongate channel of FIG. 20;

FIG. 22 is a rear perspective view of an anvil mounting portion of ananvil in accordance with at least one embodiment;

FIG. 23 is a rear perspective view of an anvil mounting portion ofanother anvil in accordance with at least one embodiment;

FIG. 24 is a rear perspective view of an anvil mounting portion ofanother anvil in accordance with at least one embodiment;

FIG. 25 is a perspective view of an anvil in accordance with at leastone embodiment;

FIG. 26 is an exploded perspective view of the anvil of FIG. 25;

FIG. 27 is a cross-sectional end view of the anvil of FIG. 25;

FIG. 28 is a perspective view of another anvil in accordance with atleast one embodiment;

FIG. 29 is an exploded perspective view of the anvil embodiment of FIG.28;

FIG. 30 is a top view of a distal end portion of an anvil body portionof the anvil of FIG. 28;

FIG. 31 is a top view of a distal end portion of an anvil body portionof another anvil in accordance with at least one embodiment;

FIG. 32 is a cross-sectional end perspective view of the anvil of FIG.31;

FIG. 33 is a cross-sectional end perspective view of another anvil inaccordance with at least one embodiment;

FIG. 34 is a cross-sectional perspective view of a staple forming pocketarrangement comprising a proximal forming pocket and a distal formingpocket, wherein each forming pocket comprises a forming surface havingan entry zone and an exit zone comprising different radii of curvature;

FIG. 35 is a plan view of the staple forming pocket arrangement of FIG.34;

FIG. 36 is a cross-sectional view of the staple forming pocketarrangement of FIG. 34 taken along line 36-36 in FIG. 35;

FIG. 37 is a cross-sectional view of the staple forming pocketarrangement of FIG. 34 taken along line 37-37 in FIG. 35;

FIG. 38 is a cross-sectional view of the staple forming pocketarrangement of FIG. 34 taken along line 38-38 in FIG. 35;

FIG. 39 is a cross-sectional view of the staple forming pocketarrangement of FIG. 34 taken along line 39-39 in FIG. 35;

FIG. 40 is a cross-sectional perspective view of a staple forming pocketarrangement comprising a proximal forming pocket, a distal formingpocket, and primary sidewalls, wherein each forming pocket comprises apair of contoured sidewalls;

FIG. 41 is a plan view of the staple forming pocket arrangement of FIG.40;

FIG. 42 is a cross-sectional view of the staple forming pocketarrangement of FIG. 40 taken along line 42-42 in FIG. 41;

FIG. 43 is a cross-sectional view of the staple forming pocketarrangement of FIG. 40 taken along line 43-43 in FIG. 41;

FIG. 44 is a cross-sectional view of the staple forming pocketarrangement of FIG. 40 taken along line 44-44 in FIG. 41;

FIG. 45 is a cross-sectional view of the staple forming pocketarrangement of FIG. 40 taken along line 45-45 in FIG. 41;

FIG. 46 depicts a staple formed with the forming pocket arrangement ofFIG. 40 in a fully formed configuration, wherein the staple contactedthe forming pockets in an aligned state;

FIG. 47 depicts a staple formed with the forming pocket arrangement ofFIG. 40 in a fully formed configuration, wherein the staple contactedthe forming pockets in a misaligned state;

FIG. 48 is a cross-sectional perspective view of a staple forming pocketarrangement comprising a proximal forming pocket and a distal formingpocket;

FIG. 49 is a cross-sectional perspective view of a portion of the stapleforming pocket arrangement of FIG. 48;

FIG. 50 is a plan view of the staple forming pocket arrangement of FIG.48;

FIG. 51 is a cross-sectional view of the staple forming pocketarrangement of FIG. 48 taken along line 51-51 in FIG. 50;

FIG. 52 is a cross-sectional view of the staple forming pocketarrangement of FIG. 48 taken along line 52-52 in the entry zone of thedistal forming pocket of FIG. 50;

FIG. 53 is a cross-sectional view of the staple forming pocketarrangement of FIG. 48 taken along line 53-53 in the transition zone ofthe distal forming pocket in FIG. 50;

FIG. 54 is a cross-sectional view of the staple forming pocketarrangement of FIG. 48 taken along line 54-54 in the exit zone of thedistal forming pocket of FIG. 50;

FIG. 54A is a partial negative view of a forming pocket of the stapleforming pocket arrangements of FIG. 48, wherein the partial negativeview comprises various slices taken in multiple planes along the formingpocket which are perpendicular to a tissue-facing surface of the stapleforming pocket arrangement and a pocket axis of the staple formingpocket arrangement;

FIG. 54B is a table comprising the dimensions of the slices of FIG. 54Awhich are labeled in FIG. 54A;

FIG. 54C is a cross-sectional view of the forming pocket arrangement ofFIG. 48 taken along a pocket axis of the forming pocket arrangement ofFIG. 48, wherein various dimensions of the forming pocket arrangementare labeled thereon;

FIG. 55 is a cross-sectional perspective view of a staple forming pocketarrangement comprising a proximal forming pocket and a distal formingpocket;

FIG. 56 is a plan view of the staple forming pocket arrangement of FIG.55;

FIG. 57 is a cross-sectional view of the staple forming pocketarrangement of FIG. 55 taken along line 57-57 in FIG. 56;

FIG. 58 is a cross-sectional view of the staple forming pocketarrangement of FIG. 55 taken along line 58-58 in the entry zone of thedistal forming pocket of FIG. 56;

FIG. 59 is a cross-sectional view of the staple forming pocketarrangement of FIG. 55 taken along line 59-59 in the transition zone ofthe distal forming pocket of FIG. 56;

FIG. 60 is a cross-sectional view of the staple forming pocketarrangement of FIG. 55 taken along line 60-60 in the exit forming zoneof the distal forming pocket of FIG. 56;

FIG. 60A is a partial negative view of a forming pocket of the stapleforming pocket arrangements of FIG. 55, wherein the partial negativeview comprises various slices taken in multiple planes along the formingpocket which are perpendicular to a tissue-facing surface of the stapleforming pocket arrangement and a pocket axis of the staple formingpocket arrangement;

FIG. 60B is a table comprising the dimensions of the slices of FIG. 60Awhich are labeled in FIG. 60A;

FIG. 60C is a cross-sectional view of the forming pocket arrangement ofFIG. 55 taken along a pocket axis of the forming pocket arrangement ofFIG. 55, wherein various dimensions of the forming pocket arrangementare labeled thereon;

FIG. 61 is a cross-sectional perspective view of a staple forming pocketarrangement comprising a proximal forming pocket and a distal formingpocket;

FIG. 62 is a plan view of the staple forming pocket arrangement of FIG.61;

FIG. 63 is a cross-sectional view of the staple forming pocketarrangement of FIG. 61 taken along line 63-63 in FIG. 62;

FIG. 64 is a cross-sectional view of the staple forming pocketarrangement of FIG. 61 taken along line 64-64 in the entry forming zoneof the distal forming pocket of FIG. 62;

FIG. 65 is a cross-sectional view of the staple forming pocketarrangement of FIG. 61 taken along line 65-65 in the entry forming zoneof the distal forming pocket of FIG. 62;

FIG. 66 is a cross-sectional view of the staple forming pocketarrangement of FIG. 61 taken along line 66-66 in the transition zone ofthe distal forming pocket of FIG. 62;

FIG. 67 is a cross-sectional view of the staple forming pocketarrangement of FIG. 61 taken along line 67-67 in the exit forming zoneof the distal forming pocket of FIG. 62;

FIG. 67A is a partial negative view of a forming pocket of the stapleforming pocket arrangements of FIG. 61, wherein the partial negativeview comprises various slices taken in multiple planes along the formingpocket which are perpendicular to a tissue-facing surface of the stapleforming pocket arrangement and a pocket axis of the staple formingpocket arrangement;

FIG. 67B is a table comprising the dimensions of the slices of FIG. 67Awhich are labeled in FIG. 67A;

FIG. 67C is a cross-sectional view of the forming pocket arrangement ofFIG. 61 taken along a pocket axis of the forming pocket arrangement ofFIG. 61, wherein various dimensions of the forming pocket arrangementare labeled thereon;

FIG. 68 is a plan view of a staple formed with the forming pocketarrangement of FIG. 55 in a fully formed configuration, wherein thestaple contacted the forming pockets in a misaligned state;

FIG. 69 is an elevation view of the staple of FIG. 68;

FIG. 70 is a cross-sectional elevation view of a surgical end effectorwith various components removed depicting an anvil and a staplecartridge having a plurality of staples, further depicting the endeffector in a closed position in which a uniform tissue gap is definedbetween the staple cartridge and the anvil, and further depicting thestaples fired from the staple cartridge and formed to a uniform heightby forming pockets in the anvil;

FIG. 71 is a cross-sectional elevation view of a surgical end effectorwith various components removed depicting an anvil and a staplecartridge having a plurality of staples, wherein the anvil comprises astepped tissue compression surface, further depicting the end effectorin a closed position in which a variable tissue gap is defined betweenthe staple cartridge and the anvil, and further depicting the staplesfired from the staple cartridge and formed to a uniform height byforming pockets in the anvil;

FIG. 72 is a cross-sectional elevation view of a surgical end effectorwith various components removed depicting an anvil and a staplecartridge having a plurality of staples and a stepped tissue compressionsurface, further depicting the end effector in a closed position inwhich a variable tissue gap is defined between the staple cartridge andthe anvil, and further depicting the staples fired from the staplecartridge and formed to a uniform height by forming pockets in theanvil;

FIG. 73 is a cross-sectional elevation view of a surgical end effectorwith various components removed depicting an anvil and a staplecartridge having a plurality of staples, wherein the anvil and thestaple cartridge comprise stepped tissue compression surfaces, furtherdepicting the end effector in a closed position in which a variabletissue gap is defined between the staple cartridge and the anvil, andfurther depicting the staples fired from the staple cartridge and formedto a uniform height by forming pockets in the anvil;

FIG. 74 is a partial cross-sectional perspective view of an articulationjoint for a surgical tool assembly with various components removeddepicting the articulation joint in an unarticulated position;

FIG. 75 is a partial cross-sectional plan view of the articulation jointof FIG. 74 in the unarticulated configuration;

FIG. 76 is a partial cross-sectional plan view of the articulation jointof FIG. 74 in a partially articulated configuration;

FIG. 77 is a partial cross-sectional plan view of the articulation jointof FIG. 74 in a fully articulated configuration; and

FIG. 77A is a detail view of a reinforcement feature of the articulationjoint of FIG. 74 in the fully articulated configuration of FIG. 77.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. PatentApplications that were filed on Jun. 27, 2017 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 15/634,024, entitled SURGICAL        ANVIL MANUFACTURING METHODS; now U.S. Patent Application        Publication No. 2018/0368839;    -   U.S. patent application Ser. No. 15/634,035, entitled SURGICAL        ANVIL ARRANGEMENTS; now U.S. Patent Application Publication No.        2018/0368840;    -   U.S. patent application Ser. No. 15/634,046, entitled SURGICAL        ANVIL ARRANGEMENTS; now U.S. Patent Application Publication No.        2018/0368841;    -   U.S. patent application Ser. No. 15/634,054, entitled SURGICAL        ANVIL ARRANGEMENTS; now U.S. Patent Application Publication No.        2018/0368842;    -   U.S. patent application Ser. No. 15/634,068, entitled SURGICAL        FIRING MEMBER ARRANGEMENTS; now U.S. Patent Application        Publication No. 2018/0368843;    -   U.S. patent application Ser. No. 15/634,076, entitled STAPLE        FORMING POCKET ARRANGEMENTS; now U.S. Patent Application        Publication No. 2018/0368844;    -   U.S. patent application Ser. No. 15/634,090, entitled STAPLE        FORMING POCKET ARRANGEMENTS; now U.S. Patent Application        Publication No. 2018/0368845; and    -   U.S. patent application Ser. No. 15/634,117, entitled        ARTICULATION SYSTEMS FOR SURGICAL INSTRUMENTS; now U.S. Patent        Application Publication No. 2018/0368847.

Applicant of the present application owns the following U.S. patentapplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 15/386,185, entitled SURGICAL        STAPLING INSTRUMENTS AND REPLACEABLE TOOL ASSEMBLIES THEREOF;    -   U.S. patent application Ser. No. 15/386,230, entitled        ARTICULATABLE SURGICAL STAPLING INSTRUMENTS;    -   U.S. patent application Ser. No. 15/386,221, entitled LOCKOUT        ARRANGEMENTS FOR SURGICAL END EFFECTORS;    -   U.S. patent application Ser. No. 15/386,209, entitled SURGICAL        END EFFECTORS AND FIRING MEMBERS THEREOF;    -   U.S. patent application Ser. No. 15/386,198, entitled LOCKOUT        ARRANGEMENTS FOR SURGICAL END EFFECTORS AND REPLACEABLE TOOL        ASSEMBLIES;    -   U.S. patent application Ser. No. 15/386,240, entitled SURGICAL        END EFFECTORS AND ADAPTABLE FIRING MEMBERS THEREFOR;    -   U.S. patent application Ser. No. 15/385,939, entitled STAPLE        CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES        THEREIN;    -   U.S. patent application Ser. No. 15/385,941, entitled SURGICAL        TOOL ASSEMBLIES WITH CLUTCHING ARRANGEMENTS FOR SHIFTING BETWEEN        CLOSURE SYSTEMS WITH CLOSURE STROKE REDUCTION FEATURES AND        ARTICULATION AND FIRING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,943, entitled SURGICAL        STAPLING INSTRUMENTS AND STAPLE-FORMING ANVILS;    -   U.S. patent application Ser. No. 15/385,950, entitled SURGICAL        TOOL ASSEMBLIES WITH CLOSURE STROKE REDUCTION FEATURES;    -   U.S. patent application Ser. No. 15/385,945, entitled STAPLE        CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES        THEREIN;    -   U.S. patent application Ser. No. 15/385,946, entitled SURGICAL        STAPLING INSTRUMENTS AND STAPLE-FORMING ANVILS;    -   U.S. patent application Ser. No. 15/385,951, entitled SURGICAL        INSTRUMENTS WITH JAW OPENING FEATURES FOR INCREASING A JAW        OPENING DISTANCE;    -   U.S. patent application Ser. No. 15/385,953, entitled METHODS OF        STAPLING TISSUE;    -   U.S. patent application Ser. No. 15/385,954, entitled FIRING        MEMBERS WITH NON-PARALLEL JAW ENGAGEMENT FEATURES FOR SURGICAL        END EFFECTORS;    -   U.S. patent application Ser. No. 15/385,955, entitled SURGICAL        END EFFECTORS WITH EXPANDABLE TISSUE STOP ARRANGEMENTS;    -   U.S. patent application Ser. No. 15/385,948, entitled SURGICAL        STAPLING INSTRUMENTS AND STAPLE-FORMING ANVILS;    -   U.S. patent application Ser. No. 15/385,956, entitled SURGICAL        INSTRUMENTS WITH POSITIVE JAW OPENING FEATURES;    -   U.S. patent application Ser. No. 15/385,958, entitled SURGICAL        INSTRUMENTS WITH LOCKOUT ARRANGEMENTS FOR PREVENTING FIRING        SYSTEM ACTUATION UNLESS AN UNSPENT STAPLE CARTRIDGE IS PRESENT;    -   U.S. patent application Ser. No. 15/385,947, entitled STAPLE        CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES        THEREIN;    -   U.S. patent application Ser. No. 15/385,896, entitled METHOD FOR        RESETTING A FUSE OF A SURGICAL INSTRUMENT SHAFT;    -   U.S. patent application Ser. No. 15/385,898, entitled STAPLE        FORMING POCKET ARRANGEMENT TO ACCOMMODATE DIFFERENT TYPES OF        STAPLES;    -   U.S. patent application Ser. No. 15/385,899, entitled SURGICAL        INSTRUMENT COMPRISING IMPROVED JAW CONTROL;    -   U.S. patent application Ser. No. 15/385,901, entitled STAPLE        CARTRIDGE AND STAPLE CARTRIDGE CHANNEL COMPRISING WINDOWS        DEFINED THEREIN;    -   U.S. patent application Ser. No. 15/385,902, entitled SURGICAL        INSTRUMENT COMPRISING A CUTTING MEMBER;    -   U.S. patent application Ser. No. 15/385,904, entitled STAPLE        FIRING MEMBER COMPRISING A MISSING CARTRIDGE AND/OR SPENT        CARTRIDGE LOCKOUT;    -   U.S. patent application Ser. No. 15/385,905, entitled FIRING        ASSEMBLY COMPRISING A LOCKOUT;    -   U.S. patent application Ser. No. 15/385,907, entitled SURGICAL        INSTRUMENT SYSTEM COMPRISING AN END EFFECTOR LOCKOUT AND A        FIRING ASSEMBLY LOCKOUT;    -   U.S. patent application Ser. No. 15/385,908, entitled FIRING        ASSEMBLY COMPRISING A FUSE;    -   U.S. patent application Ser. No. 15/385,909, entitled FIRING        ASSEMBLY COMPRISING A MULTIPLE FAILED-STATE FUSE;    -   U.S. patent application Ser. No. 15/385,920, entitled STAPLE        FORMING POCKET ARRANGEMENTS;    -   U.S. patent application Ser. No. 15/385,913, entitled ANVIL        ARRANGEMENTS FOR SURGICAL STAPLE/FASTENERS;    -   U.S. patent application Ser. No. 15/385,914, entitled METHOD OF        DEFORMING STAPLES FROM TWO DIFFERENT TYPES OF STAPLE CARTRIDGES        WITH THE SAME SURGICAL STAPLING INSTRUMENT;    -   U.S. patent application Ser. No. 15/385,893, entitled        BILATERALLY ASYMMETRIC STAPLE FORMING POCKET PAIRS;    -   U.S. patent application Ser. No. 15/385,929, entitled CLOSURE        MEMBERS WITH CAM SURFACE ARRANGEMENTS FOR SURGICAL INSTRUMENTS        WITH SEPARATE AND DISTINCT CLOSURE AND FIRING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,911, entitled SURGICAL        STAPLE/FASTENERS WITH INDEPENDENTLY ACTUATABLE CLOSING AND        FIRING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,927, entitled SURGICAL        STAPLING INSTRUMENTS WITH SMART STAPLE CARTRIDGES;    -   U.S. patent application Ser. No. 15/385,917, entitled STAPLE        CARTRIDGE COMPRISING STAPLES WITH DIFFERENT CLAMPING BREADTHS;    -   U.S. patent application Ser. No. 15/385,900, entitled STAPLE        FORMING POCKET ARRANGEMENTS COMPRISING PRIMARY SIDEWALLS AND        POCKET SIDEWALLS;    -   U.S. patent application Ser. No. 15/385,931, entitled        NO-CARTRIDGE AND SPENT CARTRIDGE LOCKOUT ARRANGEMENTS FOR        SURGICAL STAPLE/FASTENERS;    -   U.S. patent application Ser. No. 15/385,915, entitled FIRING        MEMBER PIN ANGLE;    -   U.S. patent application Ser. No. 15/385,897, entitled STAPLE        FORMING POCKET ARRANGEMENTS COMPRISING ZONED FORMING SURFACE        GROOVES;    -   U.S. patent application Ser. No. 15/385,922, entitled SURGICAL        INSTRUMENT WITH MULTIPLE FAILURE RESPONSE MODES;    -   U.S. patent application Ser. No. 15/385,924, entitled SURGICAL        INSTRUMENT WITH PRIMARY AND SAFETY PROCESSORS;    -   U.S. patent application Ser. No. 15/385,912, entitled SURGICAL        INSTRUMENTS WITH JAWS THAT ARE PIVOTABLE ABOUT A FIXED AXIS AND        INCLUDE SEPARATE AND DISTINCT CLOSURE AND FIRING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,910, entitled ANVIL        HAVING A KNIFE SLOT WIDTH;    -   U.S. patent application Ser. No. 15/385,906, entitled FIRING        MEMBER PIN CONFIGURATIONS;    -   U.S. patent application Ser. No. 15/386,188, entitled STEPPED        STAPLE CARTRIDGE WITH ASYMMETRICAL STAPLES;    -   U.S. patent application Ser. No. 15/386,192, entitled STEPPED        STAPLE CARTRIDGE WITH TISSUE RETENTION AND GAP SETTING FEATURES;    -   U.S. patent application Ser. No. 15/386,206, entitled STAPLE        CARTRIDGE WITH DEFORMABLE DRIVER RETENTION FEATURES;    -   U.S. patent application Ser. No. 15/386,226, entitled DURABILITY        FEATURES FOR END EFFECTORS AND FIRING ASSEMBLIES OF SURGICAL        STAPLING INSTRUMENTS;    -   U.S. patent application Ser. No. 15/386,222, entitled SURGICAL        STAPLING INSTRUMENTS HAVING END EFFECTORS WITH POSITIVE OPENING        FEATURES;    -   U.S. patent application Ser. No. 15/386,236, entitled CONNECTION        PORTIONS FOR DEPOSABLE LOADING UNITS FOR SURGICAL STAPLING        INSTRUMENTS;    -   U.S. patent application Ser. No. 15/385,887, entitled METHOD FOR        ATTACHING A SHAFT ASSEMBLY TO A SURGICAL INSTRUMENT AND,        ALTERNATIVELY, TO A SURGICAL ROBOT;    -   U.S. patent application Ser. No. 15/385,889, entitled SHAFT        ASSEMBLY COMPRISING A MANUALLY-OPERABLE RETRACTION SYSTEM FOR        USE WITH A MOTORIZED SURGICAL INSTRUMENT SYSTEM;    -   U.S. patent application Ser. No. 15/385,890, entitled SHAFT        ASSEMBLY COMPRISING SEPARATELY ACTUATABLE AND RETRACTABLE        SYSTEMS;    -   U.S. patent application Ser. No. 15/385,891, entitled SHAFT        ASSEMBLY COMPRISING A CLUTCH CONFIGURED TO ADAPT THE OUTPUT OF A        ROTARY FIRING MEMBER TO TWO DIFFERENT SYSTEMS;    -   U.S. patent application Ser. No. 15/385,892, entitled SURGICAL        SYSTEM COMPRISING A FIRING MEMBER ROTATABLE INTO AN ARTICULATION        STATE TO ARTICULATE AN END EFFECTOR OF THE SURGICAL SYSTEM;    -   U.S. patent application Ser. No. 15/385,894, entitled SHAFT        ASSEMBLY COMPRISING A LOCKOUT;    -   U.S. patent application Ser. No. 15/385,895, entitled SHAFT        ASSEMBLY COMPRISING FIRST AND SECOND ARTICULATION LOCKOUTS;    -   U.S. patent application Ser. No. 15/385,916, entitled SURGICAL        STAPLING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,918, entitled SURGICAL        STAPLING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,919, entitled SURGICAL        STAPLING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,921, entitled SURGICAL        STAPLE/FASTENER CARTRIDGE WITH MOVABLE CAMMING MEMBER CONFIGURED        TO DISENGAGE FIRING MEMBER LOCKOUT FEATURES;    -   U.S. patent application Ser. No. 15/385,923, entitled SURGICAL        STAPLING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,925, entitled JAW        ACTUATED LOCK ARRANGEMENTS FOR PREVENTING ADVANCEMENT OF A        FIRING MEMBER IN A SURGICAL END EFFECTOR UNLESS AN UNFIRED        CARTRIDGE IS INSTALLED IN THE END EFFECTOR;    -   U.S. patent application Ser. No. 15/385,926, entitled AXIALLY        MOVABLE CLOSURE SYSTEM ARRANGEMENTS FOR APPLYING CLOSURE MOTIONS        TO JAWS OF SURGICAL INSTRUMENTS;    -   U.S. patent application Ser. No. 15/385,928, entitled PROTECTIVE        COVER ARRANGEMENTS FOR A JOINT INTERFACE BETWEEN A MOVABLE JAW        AND ACTUATOR SHAFT OF A SURGICAL INSTRUMENT;    -   U.S. patent application Ser. No. 15/385,930, entitled SURGICAL        END EFFECTOR WITH TWO SEPARATE COOPERATING OPENING FEATURES FOR        OPENING AND CLOSING END EFFECTOR JAWS;    -   U.S. patent application Ser. No. 15/385,932, entitled        ARTICULATABLE SURGICAL END EFFECTOR WITH ASYMMETRIC SHAFT        ARRANGEMENT;    -   U.S. patent application Ser. No. 15/385,933, entitled        ARTICULATABLE SURGICAL INSTRUMENT WITH INDEPENDENT PIVOTABLE        LINKAGE DISTAL OF AN ARTICULATION LOCK;    -   U.S. patent application Ser. No. 15/385,934, entitled        ARTICULATION LOCK ARRANGEMENTS FOR LOCKING AN END EFFECTOR IN AN        ARTICULATED POSITION IN RESPONSE TO ACTUATION OF A JAW CLOSURE        SYSTEM;    -   U.S. patent application Ser. No. 15/385,935, entitled LATERALLY        ACTUATABLE ARTICULATION LOCK ARRANGEMENTS FOR LOCKING AN END        EFFECTOR OF A SURGICAL INSTRUMENT IN AN ARTICULATED        CONFIGURATION; and    -   U.S. patent application Ser. No. 15/385,936, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH ARTICULATION STROKE        AMPLIFICATION FEATURES.

Applicant of the present application owns the following U.S. patentapplications that were filed on Jun. 24, 2016 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 15/191,775, entitled STAPLE        CARTRIDGE COMPRISING WIRE STAPLES AND STAMPED STAPLES;    -   U.S. patent application Ser. No. 15/191,807, entitled STAPLING        SYSTEM FOR USE WITH WIRE STAPLES AND STAMPED STAPLES;    -   U.S. patent application Ser. No. 15/191,834, entitled STAMPED        STAPLES AND STAPLE CARTRIDGES USING THE SAME;    -   U.S. patent application Ser. No. 15/191,788, entitled STAPLE        CARTRIDGE COMPRISING OVERDRIVEN STAPLES; and    -   U.S. patent application Ser. No. 15/191,818, entitled STAPLE        CARTRIDGE COMPRISING OFFSET LONGITUDINAL STAPLE ROWS.

Applicant of the present application owns the following U.S. patentapplications that were filed on Jun. 24, 2016 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. Design patent application Ser. No. 29/569,218, entitled        SURGICAL FASTENER;    -   U.S. Design patent application Ser. No. 29/569,227, entitled        SURGICAL FASTENER;    -   U.S. Design patent application Ser. No. 29/569,259, entitled        SURGICAL FASTENER CARTRIDGE; and    -   U.S. Design patent application Ser. No. 29/569,264, entitled        SURGICAL FASTENER CARTRIDGE.

Applicant of the present application owns the following patentapplications that were filed on Apr. 1, 2016 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 15/089,325, entitled METHOD FOR        OPERATING A SURGICAL STAPLING SYSTEM;    -   U.S. patent application Ser. No. 15/089,321, entitled MODULAR        SURGICAL STAPLING SYSTEM COMPRISING A DISPLAY;    -   U.S. patent application Ser. No. 15/089,326, entitled SURGICAL        STAPLING SYSTEM COMPRISING A DISPLAY INCLUDING A RE-ORIENTABLE        DISPLAY FIELD;    -   U.S. patent application Ser. No. 15/089,263, entitled SURGICAL        INSTRUMENT HANDLE ASSEMBLY WITH RECONFIGURABLE GRIP PORTION;    -   U.S. patent application Ser. No. 15/089,262, entitled ROTARY        POWERED SURGICAL INSTRUMENT WITH MANUALLY ACTUATABLE BAILOUT        SYSTEM;    -   U.S. patent application Ser. No. 15/089,277, entitled SURGICAL        CUTTING AND STAPLING END EFFECTOR WITH ANVIL CONCENTRIC DRIVE        MEMBER;    -   U.S. patent application Ser. No. 15/089,296, entitled        INTERCHANGEABLE SURGICAL TOOL ASSEMBLY WITH A SURGICAL END        EFFECTOR THAT IS SELECTIVELY ROTATABLE ABOUT A SHAFT AXIS;    -   U.S. patent application Ser. No. 15/089,258, entitled SURGICAL        STAPLING SYSTEM COMPRISING A SHIFTABLE TRANSMISSION;    -   U.S. patent application Ser. No. 15/089,278, entitled SURGICAL        STAPLING SYSTEM CONFIGURED TO PROVIDE SELECTIVE CUTTING OF        TISSUE;    -   U.S. patent application Ser. No. 15/089,284, entitled SURGICAL        STAPLING SYSTEM COMPRISING A CONTOURABLE SHAFT;    -   U.S. patent application Ser. No. 15/089,295, entitled SURGICAL        STAPLING SYSTEM COMPRISING A TISSUE COMPRESSION LOCKOUT;    -   U.S. patent application Ser. No. 15/089,300, entitled SURGICAL        STAPLING SYSTEM COMPRISING AN UNCLAMPING LOCKOUT;    -   U.S. patent application Ser. No. 15/089,196, entitled SURGICAL        STAPLING SYSTEM COMPRISING A JAW CLOSURE LOCKOUT;    -   U.S. patent application Ser. No. 15/089,203, entitled SURGICAL        STAPLING SYSTEM COMPRISING A JAW ATTACHMENT LOCKOUT;    -   U.S. patent application Ser. No. 15/089,210, entitled SURGICAL        STAPLING SYSTEM COMPRISING A SPENT CARTRIDGE LOCKOUT;    -   U.S. patent application Ser. No. 15/089,324, entitled SURGICAL        INSTRUMENT COMPRISING A SHIFTING MECHANISM;    -   U.S. patent application Ser. No. 15/089,335, entitled SURGICAL        STAPLING INSTRUMENT COMPRISING MULTIPLE LOCKOUTS;    -   U.S. patent application Ser. No. 15/089,339, entitled SURGICAL        STAPLING INSTRUMENT;    -   U.S. patent application Ser. No. 15/089,253, entitled SURGICAL        STAPLING SYSTEM CONFIGURED TO APPLY ANNULAR ROWS OF STAPLES        HAVING DIFFERENT HEIGHTS;    -   U.S. patent application Ser. No. 15/089,304, entitled SURGICAL        STAPLING SYSTEM COMPRISING A GROOVED FORMING POCKET;    -   U.S. patent application Ser. No. 15/089,331, entitled ANVIL        MODIFICATION MEMBERS FOR SURGICAL STAPLE/FASTENERS;    -   U.S. patent application Ser. No. 15/089,336, entitled STAPLE        CARTRIDGES WITH ATRAUMATIC FEATURES;    -   U.S. patent application Ser. No. 15/089,312, entitled CIRCULAR        STAPLING SYSTEM COMPRISING AN INCISABLE TISSUE SUPPORT;    -   U.S. patent application Ser. No. 15/089,309, entitled CIRCULAR        STAPLING SYSTEM COMPRISING ROTARY FIRING SYSTEM; and    -   U.S. patent application Ser. No. 15/089,349, entitled CIRCULAR        STAPLING SYSTEM COMPRISING LOAD CONTROL.

Applicant of the present application also owns the U.S. patentapplications identified below which were filed on Dec. 31, 2015 whichare each herein incorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/984,488, entitled MECHANISMS        FOR COMPENSATING FOR BATTERY PACK FAILURE IN POWERED SURGICAL        INSTRUMENTS;    -   U.S. patent application Ser. No. 14/984,525, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS; and    -   U.S. patent application Ser. No. 14/984,552, entitled SURGICAL        INSTRUMENTS WITH SEPARABLE MOTORS AND MOTOR CONTROL CIRCUITS.

Applicant of the present application also owns the U.S. patentapplications identified below which were filed on Feb. 9, 2016 which areeach herein incorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 15/019,220, entitled SURGICAL        INSTRUMENT WITH ARTICULATING AND AXIALLY TRANSLATABLE END        EFFECTOR;    -   U.S. patent application Ser. No. 15/019,228, entitled SURGICAL        INSTRUMENTS WITH MULTIPLE LINK ARTICULATION ARRANGEMENTS;    -   U.S. patent application Ser. No. 15/019,196, entitled SURGICAL        INSTRUMENT ARTICULATION MECHANISM WITH SLOTTED SECONDARY        CONSTRAINT;    -   U.S. patent application Ser. No. 15/019,206, entitled SURGICAL        INSTRUMENTS WITH AN END EFFECTOR THAT IS HIGHLY ARTICULATABLE        RELATIVE TO AN ELONGATE SHAFT ASSEMBLY;    -   U.S. patent application Ser. No. 15/019,215, entitled SURGICAL        INSTRUMENTS WITH NON-SYMMETRICAL ARTICULATION ARRANGEMENTS;    -   U.S. patent application Ser. No. 15/019,227, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH SINGLE ARTICULATION LINK        ARRANGEMENTS;    -   U.S. patent application Ser. No. 15/019,235, entitled SURGICAL        INSTRUMENTS WITH TENSIONING ARRANGEMENTS FOR CABLE DRIVEN        ARTICULATION SYSTEMS;    -   U.S. patent application Ser. No. 15/019,230, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH OFF-AXIS FIRING BEAM        ARRANGEMENTS; and    -   U.S. patent application Ser. No. 15/019,245, entitled SURGICAL        INSTRUMENTS WITH CLOSURE STROKE REDUCTION ARRANGEMENTS.

Applicant of the present application also owns the U.S. patentapplications identified below which were filed on Feb. 12, 2016 whichare each herein incorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 15/043,254, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS;    -   U.S. patent application Ser. No. 15/043,259, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS;    -   U.S. patent application Ser. No. 15/043,275, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS; and    -   U.S. patent application Ser. No. 15/043,289, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS.

Applicant of the present application owns the following patentapplications that were filed on Jun. 18, 2015 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/742,925, entitled SURGICAL        END EFFECTORS WITH POSITIVE JAW OPENING ARRANGEMENTS, now U.S.        Patent Application Publication No. 2016/0367256;    -   U.S. patent application Ser. No. 14/742,941, entitled SURGICAL        END EFFECTORS WITH DUAL CAM ACTUATED JAW CLOSING FEATURES, now        U.S. Patent Application Publication No. 2016/0367248;    -   U.S. patent application Ser. No. 14/742,914, entitled MOVABLE        FIRING BEAM SUPPORT ARRANGEMENTS FOR ARTICULATABLE SURGICAL        INSTRUMENTS, now U.S. Patent Application Publication No.        2016/0367255;    -   U.S. patent application Ser. No. 14/742,900, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH COMPOSITE FIRING BEAM        STRUCTURES WITH CENTER FIRING SUPPORT MEMBER FOR ARTICULATION        SUPPORT, now U.S. Patent Application Publication No.        2016/0367254;    -   U.S. patent application Ser. No. 14/742,885, entitled DUAL        ARTICULATION DRIVE SYSTEM ARRANGEMENTS FOR ARTICULATABLE        SURGICAL INSTRUMENTS, now U.S. Patent Application Publication        No. 2016/0367246; and    -   U.S. patent application Ser. No. 14/742,876, entitled PUSH/PULL        ARTICULATION DRIVE SYSTEMS FOR ARTICULATABLE SURGICAL        INSTRUMENTS, now U.S. Patent Application Publication No.        2016/0367245.

Applicant of the present application owns the following patentapplications that were filed on Mar. 6, 2015 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/640,746, entitled POWERED        SURGICAL INSTRUMENT, now U.S. Patent Application Publication No.        2016/0256184;    -   U.S. patent application Ser. No. 14/640,795, entitled MULTIPLE        LEVEL THRESHOLDS TO MODIFY OPERATION OF POWERED SURGICAL        INSTRUMENTS, now U.S. Patent Application Publication No.        2016/02561185;    -   U.S. patent application Ser. No. 14/640,832, entitled ADAPTIVE        TISSUE COMPRESSION TECHNIQUES TO ADJUST CLOSURE RATES FOR        MULTIPLE TISSUE TYPES, now U.S. Patent Application Publication        No. 2016/0256154;    -   U.S. patent application Ser. No. 14/640,935, entitled OVERLAID        MULTI SENSOR RADIO FREQUENCY (RF) ELECTRODE SYSTEM TO MEASURE        TISSUE COMPRESSION, now U.S. Patent Application Publication No.        2016/0256071;    -   U.S. patent application Ser. No. 14/640,831, entitled MONITORING        SPEED CONTROL AND PRECISION INCREMENTING OF MOTOR FOR POWERED        SURGICAL INSTRUMENTS, now U.S. Patent Application Publication        No. 2016/0256153;    -   U.S. patent application Ser. No. 14/640,859, entitled TIME        DEPENDENT EVALUATION OF SENSOR DATA TO DETERMINE STABILITY,        CREEP, AND VISCOELASTIC ELEMENTS OF MEASURES, now U.S. Patent        Application Publication No. 2016/0256187;    -   U.S. patent application Ser. No. 14/640,817, entitled        INTERACTIVE FEEDBACK SYSTEM FOR POWERED SURGICAL INSTRUMENTS,        now U.S. Patent Application Publication No. 2016/0256186;    -   U.S. patent application Ser. No. 14/640,844, entitled CONTROL        TECHNIQUES AND SUB-PROCESSOR CONTAINED WITHIN MODULAR SHAFT WITH        SELECT CONTROL PROCESSING FROM HANDLE, now U.S. Patent        Application Publication No. 2016/0256155;    -   U.S. patent application Ser. No. 14/640,837, entitled SMART        SENSORS WITH LOCAL SIGNAL PROCESSING, now U.S. Patent        Application Publication No. 2016/0256163;    -   U.S. patent application Ser. No. 14/640,765, entitled SYSTEM FOR        DETECTING THE MIS-INSERTION OF A STAPLE CARTRIDGE INTO A        SURGICAL STAPLE/FASTENER, now U.S. Patent Application        Publication No. 2016/0256160;    -   U.S. patent application Ser. No. 14/640,799, entitled SIGNAL AND        POWER COMMUNICATION SYSTEM POSITIONED ON A ROTATABLE SHAFT, now        U.S. Patent Application Publication No. 2016/0256162; and    -   U.S. patent application Ser. No. 14/640,780, entitled SURGICAL        INSTRUMENT COMPRISING A LOCKABLE BATTERY HOUSING, now U.S.        Patent Application Publication No. 2016/0256161.

Applicant of the present application owns the following patentapplications that were filed on Feb. 27, 2015, and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/633,576, entitled SURGICAL        INSTRUMENT SYSTEM COMPRISING AN INSPECTION STATION, now U.S.        Patent Application Publication No. 2016/0249919;    -   U.S. patent application Ser. No. 14/633,546, entitled SURGICAL        APPARATUS CONFIGURED TO ASSESS WHETHER A PERFORMANCE PARAMETER        OF THE SURGICAL APPARATUS IS WITHIN AN ACCEPTABLE PERFORMANCE        BAND, now U.S. Patent Application Publication No. 2016/0249915;    -   U.S. patent application Ser. No. 14/633,560, entitled SURGICAL        CHARGING SYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE        BATTERIES, now U.S. Patent Application Publication No.        2016/0249910;    -   U.S. patent application Ser. No. 14/633,566, entitled CHARGING        SYSTEM THAT ENABLES EMERGENCY RESOLUTIONS FOR CHARGING A        BATTERY, now U.S. Patent Application Publication No.        2016/0249918;    -   U.S. patent application Ser. No. 14/633,555, entitled SYSTEM FOR        MONITORING WHETHER A SURGICAL INSTRUMENT NEEDS TO BE SERVICED,        now U.S. Patent Application Publication No. 2016/0249916;    -   U.S. patent application Ser. No. 14/633,542, entitled REINFORCED        BATTERY FOR A SURGICAL INSTRUMENT, now U.S. Patent Application        Publication No. 2016/0249908;    -   U.S. patent application Ser. No. 14/633,548, entitled POWER        ADAPTER FOR A SURGICAL INSTRUMENT, now U.S. Patent Application        Publication No. 2016/0249909;    -   U.S. patent application Ser. No. 14/633,526, entitled ADAPTABLE        SURGICAL INSTRUMENT HANDLE, now U.S. Patent Application        Publication No. 2016/0249945;    -   U.S. patent application Ser. No. 14/633,541, entitled MODULAR        STAPLING ASSEMBLY, now U.S. Patent Application Publication No.        2016/0249927; and    -   U.S. patent application Ser. No. 14/633,562, entitled SURGICAL        APPARATUS CONFIGURED TO TRACK AN END-OF-LIFE PARAMETER, now U.S.        Patent Application Publication No. 2016/0249917.

Applicant of the present application owns the following patentapplications that were filed on Dec. 18, 2014 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/574,478, entitled SURGICAL        INSTRUMENT SYSTEMS COMPRISING AN ARTICULATABLE END EFFECTOR AND        MEANS FOR ADJUSTING THE FIRING STROKE OF A FIRING MEMBER, now        U.S. Patent Application Publication No. 2016/0174977;    -   U.S. patent application Ser. No. 14/574,483, entitled SURGICAL        INSTRUMENT ASSEMBLY COMPRISING LOCKABLE SYSTEMS, now U.S. Patent        Application Publication No. 2016/0174969;    -   U.S. patent application Ser. No. 14/575,139, entitled DRIVE        ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS, now U.S.        Patent Application Publication No. 2016/0174978;    -   U.S. patent application Ser. No. 14/575,148, entitled LOCKING        ARRANGEMENTS FOR DETACHABLE SHAFT ASSEMBLIES WITH ARTICULATABLE        SURGICAL END EFFECTORS, now U.S. Patent Application Publication        No. 2016/0174976;    -   U.S. patent application Ser. No. 14/575,130, entitled SURGICAL        INSTRUMENT WITH AN ANVIL THAT IS SELECTIVELY MOVABLE ABOUT A        DISCRETE NON-MOVABLE AXIS RELATIVE TO A STAPLE CARTRIDGE, now        U.S. Patent Application Publication No. 2016/0174972;    -   U.S. patent application Ser. No. 14/575,143, entitled SURGICAL        INSTRUMENTS WITH IMPROVED CLOSURE ARRANGEMENTS, now U.S. Patent        Application Publication No. 2016/0174983;    -   U.S. patent application Ser. No. 14/575,117, entitled SURGICAL        INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND MOVABLE FIRING        BEAM SUPPORT ARRANGEMENTS, now U.S. Patent Application        Publication No. 2016/0174975;    -   U.S. patent application Ser. No. 14/575,154, entitled SURGICAL        INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND IMPROVED FIRING        BEAM SUPPORT ARRANGEMENTS, now U.S. Patent Application        Publication No. 2016/0174973;    -   U.S. patent application Ser. No. 14/574,493, entitled SURGICAL        INSTRUMENT ASSEMBLY COMPRISING A FLEXIBLE ARTICULATION SYSTEM,        now U.S. Patent Application Publication No. 2016/0174970; and    -   U.S. patent application Ser. No. 14/574,500, entitled SURGICAL        INSTRUMENT ASSEMBLY COMPRISING A LOCKABLE ARTICULATION SYSTEM,        now U.S. Patent Application Publication No. 2016/0174971.

Applicant of the present application owns the following patentapplications that were filed on Mar. 1, 2013 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 13/782,295, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR        SIGNAL COMMUNICATION, now U.S. Patent Application Publication        No. 2014/0246471;    -   U.S. patent application Ser. No. 13/782,323, entitled ROTARY        POWERED ARTICULATION JOINTS FOR SURGICAL INSTRUMENTS, now U.S.        Patent Application Publication No. 2014/0246472;    -   U.S. patent application Ser. No. 13/782,338, entitled THUMBWHEEL        SWITCH ARRANGEMENTS FOR SURGICAL INSTRUMENTS, now U.S. Patent        Application Publication No. 2014/0249557;    -   U.S. patent application Ser. No. 13/782,499, entitled        ELECTROMECHANICAL SURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT,        now U.S. Pat. No. 9,358,003;    -   U.S. patent application Ser. No. 13/782,460, entitled MULTIPLE        PROCESSOR MOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS, now        U.S. Pat. No. 9,554,794;    -   U.S. patent application Ser. No. 13/782,358, entitled JOYSTICK        SWITCH ASSEMBLIES FOR SURGICAL INSTRUMENTS, now U.S. Pat. No.        9,326,767;    -   U.S. patent application Ser. No. 13/782,481, entitled SENSOR        STRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR, now        U.S. Pat. No. 9,468,438;    -   U.S. patent application Ser. No. 13/782,518, entitled CONTROL        METHODS FOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT        PORTIONS, now U.S. Patent Application Publication No.        2014/0246475;    -   U.S. patent application Ser. No. 13/782,375, entitled ROTARY        POWERED SURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM,        now U.S. Pat. No. 9,398,911; and    -   U.S. patent application Ser. No. 13/782,536, entitled SURGICAL        INSTRUMENT SOFT STOP, now U.S. Pat. No. 9,307,986.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 14, 2013 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 13/803,097, entitled        ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, now        U.S. Patent Application Publication No. 2014/0263542;    -   U.S. patent application Ser. No. 13/803,193, entitled CONTROL        ARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT, now        U.S. Pat. No. 9,332,987;    -   U.S. patent application Ser. No. 13/803,053, entitled        INTERCHANGEABLE SHAFT ASSEMBLIES FOR USE WITH A SURGICAL        INSTRUMENT, now U.S. Patent Application Publication No.        2014/0263564;    -   U.S. patent application Ser. No. 13/803,086, entitled        ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION        LOCK, now U.S. Patent Application Publication No. 2014/0263541;    -   U.S. patent application Ser. No. 13/803,210, entitled SENSOR        ARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL        INSTRUMENTS, now U.S. Patent Application Publication No.        2014/0263538;    -   U.S. patent application Ser. No. 13/803,148, entitled        MULTI-FUNCTION MOTOR FOR A SURGICAL INSTRUMENT, now U.S. Patent        Application Publication No. 2014/0263554;    -   U.S. patent application Ser. No. 13/803,066, entitled DRIVE        SYSTEM LOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS,        now U.S. Pat. No. 9,629,623;    -   U.S. patent application Ser. No. 13/803,117, entitled        ARTICULATION CONTROL SYSTEM FOR ARTICULATABLE SURGICAL        INSTRUMENTS, now U.S. Pat. No. 9,351,726;    -   U.S. patent application Ser. No. 13/803,130, entitled DRIVE        TRAIN CONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now        U.S. Pat. No. 9,351,727; and    -   U.S. patent application Ser. No. 13/803,159, entitled METHOD AND        SYSTEM FOR OPERATING A SURGICAL INSTRUMENT, now U.S. Patent        Application Publication No. 2014/0277017.

Applicant of the present application also owns the following patentapplication that was filed on Mar. 7, 2014 and is herein incorporated byreference in its entirety:

-   -   U.S. patent application Ser. No. 14/200,111, entitled CONTROL        SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Pat. No. 9,629,629.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 26, 2014 and are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/226,106, entitled POWER        MANAGEMENT CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S.        Patent Application Publication No. 2015/0272582;    -   U.S. patent application Ser. No. 14/226,099, entitled        STERILIZATION VERIFICATION CIRCUIT, now U.S. Patent Application        Publication No. 2015/0272581;    -   U.S. patent application Ser. No. 14/226,094, entitled        VERIFICATION OF NUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT, now        U.S. Patent Application Publication No. 2015/0272580;    -   U.S. patent application Ser. No. 14/226,117, entitled POWER        MANAGEMENT THROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE        UP CONTROL, now U.S. Patent Application Publication No.        2015/0272574;    -   U.S. patent application Ser. No. 14/226,075, entitled MODULAR        POWERED SURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES,        now U.S. Patent Application Publication No. 2015/0272579;    -   U.S. patent application Ser. No. 14/226,093, entitled FEEDBACK        ALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS,        now U.S. Patent Application Publication No. 2015/0272569;    -   U.S. patent application Ser. No. 14/226,116, entitled SURGICAL        INSTRUMENT UTILIZING SENSOR ADAPTATION, now U.S. Patent        Application Publication No. 2015/0272571;    -   U.S. patent application Ser. No. 14/226,071, entitled SURGICAL        INSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR, now U.S.        Patent Application Publication No. 2015/0272578;    -   U.S. patent application Ser. No. 14/226,097, entitled SURGICAL        INSTRUMENT COMPRISING INTERACTIVE SYSTEMS, now U.S. Patent        Application Publication No. 2015/0272570;    -   U.S. patent application Ser. No. 14/226,126, entitled INTERFACE        SYSTEMS FOR USE WITH SURGICAL INSTRUMENTS, now U.S. Patent        Application Publication No. 2015/0272572;    -   U.S. patent application Ser. No. 14/226,133, entitled MODULAR        SURGICAL INSTRUMENT SYSTEM, now U.S. Patent Application        Publication No. 2015/0272557;    -   U.S. patent application Ser. No. 14/226,081, entitled SYSTEMS        AND METHODS FOR CONTROLLING A SEGMENTED CIRCUIT, now U.S. Patent        Application Publication No. 2015/0277471;    -   U.S. patent application Ser. No. 14/226,076, entitled POWER        MANAGEMENT THROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE        PROTECTION, now U.S. Patent Application Publication No.        2015/0280424;    -   U.S. patent application Ser. No. 14/226,111, entitled SURGICAL        STAPLING INSTRUMENT SYSTEM, now U.S. Patent Application        Publication No. 2015/0272583; and    -   U.S. patent application Ser. No. 14/226,125, entitled SURGICAL        INSTRUMENT COMPRISING A ROTATABLE SHAFT, now U.S. Patent        Application Publication No. 2015/0280384.

Applicant of the present application also owns the following patentapplications that were filed on Sep. 5, 2014 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/479,103, entitled CIRCUITRY        AND SENSORS FOR POWERED MEDICAL DEVICE, now U.S. Patent        Application Publication No. 2016/0066912;    -   U.S. patent application Ser. No. 14/479,119, entitled ADJUNCT        WITH INTEGRATED SENSORS TO QUANTIFY TISSUE COMPRESSION, now U.S.        Patent Application Publication No. 2016/0066914;    -   U.S. patent application Ser. No. 14/478,908, entitled MONITORING        DEVICE DEGRADATION BASED ON COMPONENT EVALUATION, now U.S.        Patent Application Publication No. 2016/0066910;    -   U.S. patent application Ser. No. 14/478,895, entitled MULTIPLE        SENSORS WITH ONE SENSOR AFFECTING A SECOND SENSOR'S OUTPUT OR        INTERPRETATION, now U.S. Patent Application Publication No.        2016/0066909;    -   U.S. patent application Ser. No. 14/479,110, entitled POLARITY        OF HALL MAGNET TO DETECT MISLOADED CARTRIDGE, now U.S. Patent        Application Publication No. 2016/0066915;    -   U.S. patent application Ser. No. 14/479,098, entitled SMART        CARTRIDGE WAKE UP OPERATION AND DATA RETENTION, now U.S. Patent        Application Publication No. 2016/0066911;    -   U.S. patent application Ser. No. 14/479,115, entitled MULTIPLE        MOTOR CONTROL FOR POWERED MEDICAL DEVICE, now U.S. Patent        Application Publication No. 2016/0066916; and    -   U.S. patent application Ser. No. 14/479,108, entitled LOCAL        DISPLAY OF TISSUE PARAMETER STABILIZATION, now U.S. Patent        Application Publication No. 2016/0066913.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 9, 2014 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/248,590, entitled MOTOR        DRIVEN SURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS, now        U.S. Patent Application Publication No. 2014/0305987;    -   U.S. patent application Ser. No. 14/248,581, entitled SURGICAL        INSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRING DRIVE        OPERATED FROM THE SAME ROTATABLE OUTPUT, now U.S. Pat. No.        9,649,110;    -   U.S. patent application Ser. No. 14/248,595, entitled SURGICAL        INSTRUMENT SHAFT INCLUDING SWITCHES FOR CONTROLLING THE        OPERATION OF THE SURGICAL INSTRUMENT, now U.S. Patent        Application Publication No. 2014/0305988;    -   U.S. patent application Ser. No. 14/248,588, entitled POWERED        LINEAR SURGICAL STAPLE/FASTENER, now U.S. Patent Application        Publication No. 2014/0309666;    -   U.S. patent application Ser. No. 14/248,591, entitled        TRANSMISSION ARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S.        Patent Application Publication No. 2014/0305991;    -   U.S. patent application Ser. No. 14/248,584, entitled MODULAR        MOTOR DRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR        ALIGNING ROTARY DRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS,        now U.S. Patent Application Publication No. 2014/0305994;    -   U.S. patent application Ser. No. 14/248,587, entitled POWERED        SURGICAL STAPLE/FASTENER, now U.S. Patent Application        Publication No. 2014/0309665;    -   U.S. patent application Ser. No. 14/248,586, entitled DRIVE        SYSTEM DECOUPLING ARRANGEMENT FOR A SURGICAL INSTRUMENT, now        U.S. Patent Application Publication No. 2014/0305990; and    -   U.S. patent application Ser. No. 14/248,607, entitled MODULAR        MOTOR DRIVEN SURGICAL INSTRUMENTS WITH STATUS INDICATION        ARRANGEMENTS, now U.S. Patent Application Publication No.        2014/0305992.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 16, 2013 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. Provisional Patent Application Ser. No. 61/812,365,        entitled SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED        BY A SINGLE MOTOR;    -   U.S. Provisional Patent Application Ser. No. 61/812,376,        entitled LINEAR CUTTER WITH POWER;    -   U.S. Provisional Patent Application Ser. No. 61/812,382,        entitled LINEAR CUTTER WITH MOTOR AND PISTOL GRIP;    -   U.S. Provisional Patent Application Ser. No. 61/812,385,        entitled SURGICAL INSTRUMENT HANDLE WITH MULTIPLE ACTUATION        MOTORS AND MOTOR CONTROL; and    -   U.S. Provisional Patent Application Ser. No. 61/812,372,        entitled SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED        BY A SINGLE MOTOR.

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” refers to the portion closest to the clinician andthe term “distal” refers to the portion located away from the clinician.It will be further appreciated that, for convenience and clarity,spatial terms such as “vertical”, “horizontal”, “up”, and “down” may beused herein with respect to the drawings. However, surgical instrumentsare used in many orientations and positions, and these terms are notintended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongate shaft of a surgical instrument can be advanced.

A surgical stapling system can comprise a shaft and an end effectorextending from the shaft. The end effector comprises a first jaw and asecond jaw. The first jaw comprises a staple cartridge. The staplecartridge is insertable into and removable from the first jaw; however,other embodiments are envisioned in which a staple cartridge is notremovable from, or at least readily replaceable from, the first jaw. Thesecond jaw comprises an anvil configured to deform staples ejected fromthe staple cartridge. The second jaw is pivotable relative to the firstjaw about a closure axis; however, other embodiments are envisioned inwhich the first jaw is pivotable relative to the second jaw. Thesurgical stapling system further comprises an articulation jointconfigured to permit the end effector to be rotated, or articulated,relative to the shaft. The end effector is rotatable about anarticulation axis extending through the articulation joint. Otherembodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge bodyincludes a proximal end, a distal end, and a deck extending between theproximal end and the distal end. In use, the staple cartridge ispositioned on a first side of the tissue to be stapled and the anvil ispositioned on a second side of the tissue. The anvil is moved toward thestaple cartridge to compress and clamp the tissue against the deck.Thereafter, staples removably stored in the cartridge body can bedeployed into the tissue. The cartridge body includes staple cavitiesdefined therein wherein staples are removably stored in the staplecavities. The staple cavities are arranged in six longitudinal rows.Three rows of staple cavities are positioned on a first side of alongitudinal slot and three rows of staple cavities are positioned on asecond side of the longitudinal slot. Other arrangements of staplecavities and staples may be possible.

The staples are supported by staple drivers in the cartridge body. Thedrivers are movable between a first, or unfired position, and a second,or fired, position to eject the staples from the staple cavities. Thedrivers are retained in the cartridge body by a retainer which extendsaround the bottom of the cartridge body and includes resilient membersconfigured to grip the cartridge body and hold the retainer to thecartridge body. The drivers are movable between their unfired positionsand their fired positions by a sled. The sled is movable between aproximal position adjacent the proximal end and a distal positionadjacent the distal end. The sled comprises a plurality of rampedsurfaces configured to slide under the drivers and lift the drivers, andthe staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. Thefiring member is configured to contact the sled and push the sled towardthe distal end. The longitudinal slot defined in the cartridge body isconfigured to receive the firing member. The anvil also includes a slotconfigured to receive the firing member. The firing member furthercomprises a first cam which engages the first jaw and a second cam whichengages the second jaw. As the firing member is advanced distally, thefirst cam and the second cam can control the distance, or tissue gap,between the deck of the staple cartridge and the anvil. The firingmember also comprises a knife configured to incise the tissue capturedintermediate the staple cartridge and the anvil. It is desirable for theknife to be positioned at least partially proximal to the rampedsurfaces such that the staples are ejected ahead of the knife.

FIG. 1 depicts a motor-driven surgical system 10 that may be used toperform a variety of different surgical procedures. As can be seen inthat Figure, one example of the surgical system 10 includes fourinterchangeable surgical tool assemblies 100, 200, 300, and 1000 thatare each adapted for interchangeable use with a handle assembly 500.Each interchangeable surgical tool assembly 100, 200, 300, and 1000 maybe designed for use in connection with the performance of one or morespecific surgical procedures. In another surgical system embodiment, theinterchangeable surgical tool assemblies may be effectively employedwith a tool drive assembly of a robotically controlled or automatedsurgical system. For example, the surgical tool assemblies disclosedherein may be employed with various robotic systems, instruments,components and methods such as, but not limited to, those disclosed inU.S. Pat. No. 9,072,535, entitled SURGICAL STAPLING INSTRUMENTS WITHROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, which is hereby incorporatedby reference herein in its entirety.

FIG. 2 illustrates one form of an interchangeable surgical tool assembly100 that is operably coupled to the handle assembly 500. FIG. 3illustrates attachment of the interchangeable surgical tool assembly 100to the handle assembly 500. The attachment arrangement and processdepicted in FIG. 3 may also be employed in connection with attachment ofany of the interchangeable surgical tool assemblies 100, 200, 300, and1000 to a tool drive portion or tool drive housing of a robotic system.The handle assembly 500 may comprise a handle housing 502 that includesa pistol grip portion 504 that can be gripped and manipulated by theclinician. As will be briefly discussed below, the handle assembly 500operably supports a plurality of drive systems that are configured togenerate and apply various control motions to corresponding portions ofthe interchangeable surgical tool assembly 100, 200, 300, and/or 1000that is operably attached thereto.

Referring now to FIG. 3, the handle assembly 500 may further include aframe 506 that operably supports the plurality of drive systems. Forexample, the frame 506 can operably support a first or closure drivesystem, generally designated as 510, which may be employed to applyclosing and opening motions to the interchangeable surgical toolassembly 100, 200, 300, and 1000 that is operably attached or coupled tothe handle assembly 500. In at least one form, the closure drive system510 may include an actuator in the form of a closure trigger 512 that ispivotally supported by the frame 506. Such an arrangement enables theclosure trigger 512 to be manipulated by a clinician such that, when theclinician grips the pistol grip portion 504 of the handle assembly 500,the closure trigger 512 may be pivoted from a starting or “unactuated”position to an “actuated” position and more particularly to a fullycompressed or fully actuated position. In various forms, the closuredrive system 510 further includes a closure linkage assembly 514 that ispivotally coupled to the closure trigger 512 or otherwise operablyinterfaces therewith. As will be discussed in further detail below, theclosure linkage assembly 514 includes a transverse attachment pin 516that facilitates attachment to a corresponding drive system on thesurgical tool assembly. To actuate the closure drive system, theclinician depresses the closure trigger 512 towards the pistol gripportion 504. As described in further detail in U.S. patent applicationSer. No. 14/226,142, entitled SURGICAL INSTRUMENT COMPRISING A SENSORSYSTEM, now U.S. Patent Application Publication No. 2015/0272575, whichis hereby incorporated by reference in its entirety herein, the closuredrive system is configured to lock the closure trigger 512 into thefully depressed or fully actuated position when the clinician fullydepresses the closure trigger 512 to attain the full closure stroke.When the clinician desires to unlock the closure trigger 512 to permitthe closure trigger 512 to be biased to the unactuated position, theclinician simply activates a closure release button assembly 518 whichenables the closure trigger to return to unactuated position. Theclosure release button 518 may also be configured to interact withvarious sensors that communicate with a microcontroller 520 in thehandle assembly 500 for tracking the position of the closure trigger512. Further details concerning the configuration and operation of theclosure release button assembly 518 may be found in U.S. PatentApplication Publication No. 2015/0272575.

In at least one form, the handle assembly 500 and the frame 506 mayoperably support another drive system referred to herein as a firingdrive system 530 that is configured to apply firing motions tocorresponding portions of the interchangeable surgical tool assemblythat is attached thereto. As was described in detail in U.S. PatentApplication Publication No. 2015/0272575, the firing drive system 530may employ an electric motor (not shown in FIGS. 1-3) that is located inthe pistol grip portion 504 of the handle assembly 500. In variousforms, the motor may be a DC brushed driving motor having a maximumspeed of approximately 25,000 RPM, for example. In other arrangements,the motor may include a brushless motor, a cordless motor, a synchronousmotor, a stepper motor, or any other suitable electric motor. The motormay be powered by a power source 522 that in one form may comprise aremovable power pack. The power pack may support a plurality of LithiumIon (“LI”) or other suitable batteries therein. A number of batteriesmay be connected in series may be used as the power source 522 for thesurgical system 10. In addition, the power source 522 may be replaceableand/or rechargeable.

The electric motor is configured to axially drive a longitudinallymovable drive member 540 in distal and proximal directions dependingupon the polarity of the voltage applied to the motor. For example, whenthe motor is driven in one rotary direction, the longitudinally movabledrive member 540 the will be axially driven in the distal direction“DD”. When the motor is driven in the opposite rotary direction, thelongitudinally movable drive member 540 will be axially driven in aproximal direction “PD”. The handle assembly 500 can include a switch513 which can be configured to reverse the polarity applied to theelectric motor by the power source 522 or otherwise control the motor.The handle assembly 500 can also include a sensor or sensors that areconfigured to detect the position of the drive member 540 and/or thedirection in which the drive member 540 is being moved. Actuation of themotor can be controlled by a firing trigger 532 (FIG. 1) that ispivotally supported on the handle assembly 500. The firing trigger 532may be pivoted between an unactuated position and an actuated position.The firing trigger 532 may be biased into the unactuated position by aspring or other biasing arrangement such that, when the clinicianreleases the firing trigger 532, the firing trigger 532 may be pivotedor otherwise returned to the unactuated position by the spring orbiasing arrangement. In at least one form, the firing trigger 532 can bepositioned “outboard” of the closure trigger 512 as was discussed above.As discussed in U.S. Patent Application Publication No. 2015/0272575,the handle assembly 500 may be equipped with a firing trigger safetybutton to prevent inadvertent actuation of the firing trigger 532. Whenthe closure trigger 512 is in the unactuated position, the safety buttonis contained in the handle assembly 500 where the clinician cannotreadily access the safety button and move it between a safety positionpreventing actuation of the firing trigger 532 and a firing positionwherein the firing trigger 532 may be fired. As the clinician depressesthe closure trigger 512, the safety button and the firing trigger 532pivot downwardly where they can then be manipulated by the clinician.

In at least one form, the longitudinally movable drive member 540 mayhave a rack of teeth formed thereon for meshing engagement with acorresponding drive gear arrangement that interfaces with the motor.Further details regarding those features may be found in U.S. PatentApplication Publication No. 2015/0272575. In at least one form, thehandle assembly 500 also includes a manually-actuatable “bailout”assembly that is configured to enable the clinician to manually retractthe longitudinally movable drive member 540 should the motor becomedisabled. The bailout assembly may include a lever or bailout handleassembly that is stored within the handle assembly 500 under areleasable door 550. The lever is configured to be manually pivoted intoratcheting engagement with the teeth in the drive member 540. Thus, theclinician can manually retract the drive member 540 by using the bailouthandle assembly to ratchet the drive member 5400 in the proximaldirection “PD”. U.S. patent application Ser. No. 12/249,117, entitledPOWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLYRETRACTABLE FIRING SYSTEM, now U.S. Pat. No. 8,608,045, the entiredisclosure of which is hereby incorporated by reference herein,discloses bailout arrangements that may also be employed with thevarious surgical tool assemblies disclosed herein.

Turning now to FIG. 2, the interchangeable surgical tool assembly 100includes a surgical end effector 110 that comprises a first jaw and asecond jaw. In one arrangement, the first jaw comprises an elongatechannel 112 that is configured to operably support a surgical staplecartridge 116 therein. The second jaw comprises an anvil 114 that ispivotally supported relative to the elongate channel 112. Theinterchangeable surgical tool assembly 100 also includes a lockablearticulation joint 120 which can be configured to releasably hold theend effector 110 in a desired position relative to a shaft axis SA.Details regarding various constructions and operation of the endeffector 110, the articulation joint 120 and the articulation lock areset forth in U.S. patent application Ser. No. 13/803,086, entitledARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, nowU.S. Patent Application Publication No. 2014/0263541, which is herebyincorporated by reference herein in its entirety. As can be further seenin FIGS. 2 and 3, the interchangeable surgical tool assembly 100 caninclude a proximal housing or nozzle 130 and a closure tube assembly 140which can be utilized to close and/or open the anvil 114 of the endeffector 110. As discussed in U.S. Patent Application Publication No.2015/0272575, the closure tube assembly 140 is movably supported on aspine 145 which supports an articulation driver arrangement 147configured to apply articulation motions to the surgical end effector110. The spine 145 is configured to, one, slidably support a firing bar170 therein and, two, slidably support the closure tube assembly 140which extends around the spine 145. In various circumstances, the spine145 includes a proximal end that is rotatably supported in a chassis150. See FIG. 3. In one arrangement, for example, the proximal end ofthe spine 145 is attached to a spine bearing that is configured to besupported within the chassis 150. Such an arrangement facilitates therotatable attachment of the spine 145 to the chassis 150 such that thespine 145 may be selectively rotated about a shaft axis SA relative tothe chassis 150.

Still referring to FIG. 3, the interchangeable surgical tool assembly100 includes a closure shuttle 160 that is slidably supported within thechassis 150 such that the closure shuttle 160 may be axially movedrelative to the chassis 150. As can be seen in FIG. 3, the closureshuttle 160 includes a pair of proximally-protruding hooks 162 that areconfigured to be attached to the attachment pin 516 that is attached tothe closure linkage assembly 514 in the handle assembly 500. A proximalclosure tube segment 146 of the closure tube assembly 140 is rotatablycoupled to the closure shuttle 160. Thus, when the hooks 162 are hookedover the pin 516, actuation of the closure trigger 512 will result inthe axial movement of the closure shuttle 160 and, ultimately, theclosure tube assembly 140 on the spine 145. A closure spring may also bejournaled on the closure tube assembly 140 and serves to bias theclosure tube assembly 140 in the proximal direction “PD” which can serveto pivot the closure trigger 512 into the unactuated position when theshaft assembly 100 is operably coupled to the handle assembly 500. Inuse, the closure tube assembly 140 is translated distally (direction DD)to close the anvil 114 in response to the actuation of the closuretrigger 512. The closure tube assembly 140 includes a distal closuretube segment 142 that is pivotally pinned to a distal end of a proximalclosure tube segment 146. The distal closure tube segment 142 isconfigured to axially move with the proximal closure tube segment 146relative to the surgical end effector 110. When the distal end of thedistal closure tube segment 142 strikes a proximal surface or ledge 115on the anvil 114, the anvil 114 is pivoted closed. Further detailsconcerning the closure of anvil 114 may be found in the aforementionedU.S. Patent Application Publication No. 2014/0263541 and will bediscussed in further detail below. As was also described in detail inU.S. Patent Application Publication No. 2014/0263541, the anvil 114 isopened by proximally translating the distal closure tube segment 142.The distal closure tube segment 142 has a horseshoe aperture 143 thereinthat defines a downwardly extending return tab that cooperates with ananvil tab 117 formed on the proximal end of the anvil 114 to pivot theanvil 114 back to an open position. In the fully open position, theclosure tube assembly 140 is in its proximal-most or unactuatedposition.

As was also indicated above, the interchangeable surgical tool assembly100 further includes a firing bar 170 that is supported for axial travelwithin the shaft spine 145. The firing bar 170 includes an intermediatefiring shaft portion that is configured to be attached to a distalcutting portion or knife bar that is configured for axial travel throughthe surgical end effector 110. In at least one arrangement, theinterchangeable surgical tool assembly 100 includes a clutch assemblywhich can be configured to selectively and releasably couple thearticulation driver to the firing bar 170. Further details regarding theclutch assembly features and operation may be found in U.S. PatentApplication Publication No. 2014/0263541. As discussed in U.S. PatentApplication Publication No. 2014/0263541, distal movement of the firingbar 170 can move the articulation driver arrangement 147 distally and,correspondingly, proximal movement of the firing bar 170 can move thearticulation driver arrangement 147 proximally when the clutch assemblyis in its engaged position. When the clutch assembly is in itsdisengaged position, movement of the firing bar 170 is not transmittedto the articulation driver arrangement 147 and, as a result, the firingbar 170 can move independently of the articulation driver arrangement147. The interchangeable surgical tool assembly 100 may also include aslip ring assembly which can be configured to conduct electrical powerto and/or from the end effector 110 and/or communicate signals to and/orfrom the end effector 110. Further details regarding the slip ringassembly may be found in U.S. Patent Application Publication No.2014/0263541. U.S. patent application Ser. No. 13/800,067, entitledSTAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, now U.S. PatentApplication Publication No. 2014/0263552 is incorporated by reference inits entirety. U.S. Pat. No. 9,345,481, entitled STAPLE CARTRIDGE TISSUETHICKNESS SENSOR SYSTEM, is also hereby incorporated by reference in itsentirety.

Still referring to FIG. 3, the chassis 150 has one or more taperedattachment portions 152 formed thereon that are adapted to be receivedwithin corresponding dovetail slots 507 formed within a distal end ofthe frame 506. Each dovetail slot 507 may be tapered or, stated anotherway, may be somewhat V-shaped to seatingly receive the taperedattachment portions 152 therein. As can be further seen in FIG. 3, ashaft attachment lug 172 is formed on the proximal end of the firingshaft 170. When the interchangeable surgical tool assembly 100 iscoupled to the handle assembly 500, the shaft attachment lug 172 isreceived in a firing shaft attachment cradle 542 formed in the distalend of the longitudinally movable drive member 540. The interchangeablesurgical tool assembly 100 also employs a latch system 180 forreleasably latching the shaft assembly 100 to the frame 506 of thehandle assembly 500. In at least one form, the latch system 180 includesa lock member or lock yoke 182 that is movably coupled to the chassis150, for example. The lock yoke 182 includes two proximally protrudinglock lugs 184 that are configured for releasable engagement withcorresponding lock detents or grooves 509 in the distal attachmentflange of the frame 506. In various forms, the lock yoke 182 is biasedin the proximal direction by spring or biasing member. Actuation of thelock yoke 182 may be accomplished by a latch button 186 that is slidablymounted on a latch actuator assembly that is mounted to the chassis 150.The latch button 186 may be biased in a proximal direction relative tothe lock yoke 182. As will be discussed in further detail below, thelock yoke 182 may be moved to an unlocked position by biasing the latchbutton 186 the in distal direction DD which also causes the lock yoke182 to pivot out of retaining engagement with the distal attachmentflange of the frame 506. When the lock yoke 182 is in retainingengagement with the distal attachment flange of the frame 506, the locklugs 184 are retainingly seated within the corresponding lock detents orgrooves 509 in the distal end of the frame 506. Further detailsconcerning the latching system may be found in U.S. Patent ApplicationPublication No. 2014/0263541.

To attach the interchangeable surgical tool assembly 100 to the handleassembly 500 A clinician may position the chassis 150 of theinterchangeable surgical tool assembly 100 above or adjacent to thedistal end of the frame 506 such that the tapered attachment portions152 formed on the chassis 150 are aligned with the dovetail slots 507 inthe frame 506. The clinician may then move the surgical tool assembly100 along an installation axis IA that is perpendicular to the shaftaxis SA to seat the tapered attachment portions 152 in operableengagement with the corresponding dovetail receiving slots 507 in thedistal end of the frame 506. In doing so, the shaft attachment lug 172on the firing shaft 170 will also be seated in the cradle 542 in thelongitudinally movable drive member 540 and the portions of pin 516 onthe closure link 514 will be seated in the corresponding hooks 162 inthe closure shuttle 160. As used herein, the term “operable engagement”in the context of two components means that the two components aresufficiently engaged with each other so that, upon application of anactuation motion thereto, the components carry out their intendedaction, function, and/or procedure.

Returning now to FIG. 1, the surgical system 10 includes fourinterchangeable surgical tool assemblies 100, 200, 300, and 1000 thatmay each be effectively employed with the same handle assembly 500 toperform different surgical procedures. The construction of an exemplaryform of interchangeable surgical tool assembly 100 was briefly discussedabove and is discussed in further detail in U.S. Patent ApplicationPublication No. 2014/0263541. Various details regarding interchangeablesurgical tool assemblies 200 and 300 may be found in the various U.S.patent applications which have been incorporated by reference herein.Various details regarding interchangeable surgical tool assembly 1000will be discussed in further detail below.

As illustrated in FIG. 1, each of the surgical tool assemblies 100, 200,300, and 1000 includes a pair of jaws wherein at least one of the jawsis movable to capture, manipulate, and/or clamp tissue between the twojaws. The movable jaw is moved between open and closed positions uponthe application of closure and opening motions applied thereto from thehandle assembly or the robotic or automated surgical system to which thesurgical tool assembly is operably coupled. In addition, each of theillustrated interchangeable surgical tool assemblies includes a firingmember that is configured to cut tissue and fire staples from a staplecartridge that is supported in one of the jaws in response to firingmotions applied thereto by the handle assembly or robotic system. Eachsurgical tool assembly may be uniquely designed to perform a specificprocedure, for example, to cut and fasten a particular type of andthickness of tissue within a certain area in the body. The closing,firing and articulation control systems in the handle assembly 500 orrobotic system may be configured to generate axial control motionsand/or rotary control motions depending upon the type of closing,firing, and articulation system configurations that are employed in thesurgical tool assembly. In one arrangement, one of the closure systemcontrol components moves axially from an unactuated position to itsfully actuated position when a closure control system in the handleassembly or robotic system is fully actuated. The axial distance thatthe closure tube assembly moves between its unactuated position to itsfully actuated position may be referred to herein as its “closure strokelength”. Similarly, one of the firing system control components movesaxially from its unactuated position to its fully actuated or firedposition when a firing system in the handle assembly or robotic systemis fully actuated. The axial distance that the longitudinally movabledrive member moves between its unactuated position and its fully firedposition may be referred to herein as its “firing stroke length”. Forthose surgical tool assemblies that employ articulatable end effectorarrangements, the handle assembly or robotic system may employarticulation control components that move axially through an“articulation drive stroke length”. In many circumstances, the closurestroke length, the firing stroke length, and the articulation drivestroke length are fixed for a particular handle assembly or roboticsystem. Thus, each of the surgical tool assemblies must be able toaccommodate control movements of the closure, firing, and/orarticulation components through each of their entire stroke lengthswithout placing undue stress on the surgical tool components which mightlead to damage the surgical tool assembly.

Turning now to FIGS. 4-10, the interchangeable surgical tool assembly1000 includes a surgical end effector 1100 that comprises an elongatechannel 1102 that is configured to operably support a staple cartridge1110 therein. The end effector 1100 may further include an anvil 1130that is pivotally supported relative to the elongate channel 1102. Theinterchangeable surgical tool assembly 1000 may further include anarticulation joint 1200 and an articulation lock 1210 (FIGS. 5 and 8-10)which can be configured to releasably hold the end effector 1100 in adesired articulated position relative to a shaft axis SA. Detailsregarding the construction and operation of the articulation lock 1210may be found in in U.S. patent application Ser. No. 13/803,086, entitledARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, nowU.S. Patent Application Publication No. 2014/0263541, the entiredisclosure of which is hereby incorporated by reference herein.Additional details concerning the articulation lock may also be found inU.S. patent application Ser. No. 15/019,196, filed Feb. 9, 2016,entitled SURGICAL INSTRUMENT ARTICULATION MECHANISM WITH SLOTTEDSECONDARY CONSTRAINT, the entire disclosure of which is herebyincorporated by reference herein. As can be seen in FIG. 7, theinterchangeable surgical tool assembly 1000 can further include aproximal housing or nozzle 1300 comprised of nozzle portions 1302, 1304as well as an actuator wheel portion 1306 that is configured to becoupled to the assembled nozzle portions 1302, 1304 by snaps, lugs,and/or screws, for example. The interchangeable surgical tool assembly1000 can further include a closure tube assembly 1400 which can beutilized to close and/or open the anvil 1130 of the end effector 1100 aswill be discussed in further detail below. Primarily referring now toFIGS. 8 and 9, the interchangeable surgical tool assembly 1000 caninclude a spine assembly 1500 which can be configured to support thearticulation lock 1210. The spine assembly 1500 comprises an “elastic”spine or frame member 1510 which will be described in further detailbelow. A distal end portion 1522 of the elastic spine member 1510 isattached to a distal frame segment 1560 that operably supports thearticulation lock 1210 therein. As can be seen in FIGS. 7 and 8, thespine assembly 1500 is configured to, one, slidably support a firingmember assembly 1600 therein and, two, slidably support the closure tubeassembly 1400 which extends around the spine assembly 1500. The spineassembly 1500 can also be configured to slidably support a proximalarticulation driver 1700.

As can be seen in FIG. 10, the distal frame segment 1560 is pivotallycoupled to the elongate channel 1102 by an end effector mountingassembly 1230. In one arrangement, the distal end 1562 of the distalframe segment 1560 has a pivot pin 1564 formed thereon, for example. Thepivot pin 1564 is adapted to be pivotally received within a pivot hole1234 formed in pivot base portion 1232 of the end effector mountingassembly 1230. The end effector mounting assembly 1230 is attached tothe proximal end 1103 of the elongate channel 1102 by a spring pin 1108or other suitable member. The pivot pin 1564 defines an articulationaxis B-B that is transverse to the shaft axis SA. See FIG. 4. Such anarrangement facilitates pivotal travel (i.e., articulation) of the endeffector 1100 about the articulation axis B-B relative to the spineassembly 1500.

Still referring to FIG. 10, the articulation driver 1700 has a distalend 1702 that is configured to operably engage the articulation lock1210. The articulation lock 1210 includes an articulation frame 1212that is adapted to operably engage a drive pin 1238 on the pivot baseportion 1232 of the end effector mounting assembly 1230. In addition, across-link 1237 may be linked to the drive pin 1238 and articulationframe 1212 to assist articulation of the end effector 1100. As indicatedabove, further details regarding the operation of the articulation lock1210 and the articulation frame 1212 may be found in U.S. patentapplication Ser. No. 13/803,086, now U.S. Patent Application PublicationNo. 2014/0263541. Further details regarding the end effector mountingassembly and a crosslink may be found in U.S. patent application Ser.No. 15/019,245, filed Feb. 9, 2016, entitled SURGICAL INSTRUMENTS WITHCLOSURE STROKE REDUCTION ARRANGEMENTS, the entire disclosure of which ishereby incorporated by reference herein. In various circumstances, theelastic spine member 1510 includes a proximal end 1514 which isrotatably supported in a chassis 1800. In one arrangement, the proximalend 1514 of the elastic spine member 1510 has a thread 1516 formedthereon for threaded attachment to a spine bearing that is configured tobe supported within the chassis 1800, for example. Such an arrangementfacilitates rotatable attachment of the elastic spine member 1510 to thechassis 1800 such that the spine assembly 1500 may be selectivelyrotated about a shaft axis SA relative to the chassis 1800.

Referring primarily to FIG. 7, the interchangeable surgical toolassembly 1000 includes a closure shuttle 1420 that is slidably supportedwithin the chassis 1800 such that the closure shuttle 1420 may beaxially moved relative to the chassis 1800. In one form, the closureshuttle 1420 includes a pair of proximally-protruding hooks 1421 thatare configured to be attached to the attachment pin 516 that is attachedto the closure linkage assembly 514 of the handle assembly 500 as wasdiscussed above. A proximal end 1412 of a proximal closure tube segment1410 is rotatably coupled to the closure shuttle 1420. For example, aU-shaped connector 1424 is inserted into an annular slot 1414 in theproximal end 1412 of the proximal closure tube segment 1410 and isretained within vertical slots 1422 in the closure shuttle 1420. SeeFIG. 7. Such an arrangement serves to attach the proximal closure tubesegment 1410 to the closure shuttle 1420 for axial travel therewithwhile enabling the closure tube assembly 1400 to rotate relative to theclosure shuttle 1420 about the shaft axis SA. A closure spring isjournaled on the proximal end 1412 of the proximal closure tube segment1410 and serves to bias the closure tube assembly 1400 in the proximaldirection PD which can serve to pivot the closure trigger 512 on thehandle assembly 500 (FIG. 3) into the unactuated position when theinterchangeable surgical tool assembly 1000 is operably coupled to thehandle assembly 500.

As indicated above, the illustrated interchangeable surgical toolassembly 1000 includes an articulation joint 1200. Other interchangeablesurgical tool assemblies, however, may not be capable of articulation.As can be seen in FIG. 10, upper and lower tangs 1415, 1416 protrudedistally from a distal end of the proximal closure tube segment 1410which are configured to be movably coupled to an end effector closuresleeve or distal closure tube segment 1430 of the closure tube assembly1400. As can be seen in FIG. 10, the distal closure tube segment 1430includes upper and lower tangs 1434, 1436 that protrude proximally froma proximal end thereof. An upper double pivot link 1220 includesproximal and distal pins that engage corresponding holes in the uppertangs 1415, 1434 of the proximal closure tube segment 1410 and distalclosure tube segment 1430, respectively. Similarly, a lower double pivotlink 1222 includes proximal and distal pins that engage correspondingholes in the lower tangs 1416 and 1436 of the proximal closure tubesegment 1410 and distal closure tube segment 1430, respectively. As willbe discussed in further detail below, distal and proximal axialtranslation of the closure tube assembly 1400 will result in the closingand opening of the anvil 1130 relative to the elongate channel 1102.

As mentioned above, the interchangeable surgical tool assembly 1000further includes a firing member assembly 1600 that is supported foraxial travel within the spine assembly 1500. The firing member assembly1600 includes an intermediate firing shaft portion 1602 that isconfigured to be attached to a distal cutting portion or knife bar 1610.The firing member assembly 1600 may also be referred to herein as a“second shaft” and/or a “second shaft assembly”. As can be seen in FIGS.7-10, the intermediate firing shaft portion 1602 may include alongitudinal slot 1604 in the distal end thereof which can be configuredto receive a tab on the proximal end of the knife bar 1610. Thelongitudinal slot 1604 and the proximal end of the knife bar 1610 can besized and configured to permit relative movement therebetween and cancomprise a slip joint 1612. The slip joint 1612 can permit theintermediate firing shaft portion 1602 of the firing member assembly1600 to be moved to articulate the end effector 1100 without moving, orat least substantially moving, the knife bar 1610. Once the end effector1100 has been suitably oriented, the intermediate firing shaft portion1602 can be advanced distally until a proximal sidewall of thelongitudinal slot 1604 comes into contact with the tab on the knife bar1610 to advance the knife bar 1610 and fire the staple cartridge 1110positioned within the elongate channel 1102. As can be further seen inFIGS. 8 and 9, the elastic spine member 1520 has an elongate opening orwindow 1525 therein to facilitate the assembly and insertion of theintermediate firing shaft portion 1602 into the elastic spine member1520. Once the intermediate firing shaft portion 1602 has been insertedtherein, a top frame segment 1527 may be engaged with the elastic spinemember 1520 to enclose the intermediate firing shaft portion 1602 andknife bar 1610 therein. Further description of the operation of thefiring member assembly 1600 may be found in U.S. patent application Ser.No. 13/803,086, now U.S. Patent Application Publication No.2014/0263541.

Further to the above, the interchangeable tool assembly 1000 can includea clutch assembly 1620 which can be configured to selectively andreleasably couple the articulation driver 1700 to the firing memberassembly 1600. In one form, the clutch assembly 1620 includes a lockcollar, or sleeve 1622, positioned around the firing member assembly1600 wherein the lock sleeve 1622 can be rotated between an engagedposition in which the lock sleeve 1622 couples the articulation driver1700 to the firing member assembly 1600 and a disengaged position inwhich the articulation driver 1700 is not operably coupled to the firingmember assembly 1600. When the lock sleeve 1622 is in its engagedposition, distal movement of the firing member assembly 1600 can movethe articulation driver 1700 distally and, correspondingly, proximalmovement of the firing member assembly 1600 can move the articulationdriver 1700 proximally. When the lock sleeve 1622 is in its disengagedposition, movement of the firing member assembly 1600 is not transmittedto the articulation driver 1700 and, as a result, the firing memberassembly 1600 can move independently of the articulation driver 1700. Invarious circumstances, the articulation driver 1700 can be held inposition by the articulation lock 1210 when the articulation driver 1700is not being moved in the proximal or distal directions by the firingmember assembly 1600.

Referring primarily to FIG. 7, the lock sleeve 1622 can comprise acylindrical, or an at least substantially cylindrical, body including alongitudinal aperture 1624 defined therein configured to receive thefiring member assembly 1600. The lock sleeve 1622 can comprisediametrically-opposed, inwardly-facing lock protrusions 1626, 1628 andan outwardly-facing lock member 1629. The lock protrusions 1626, 1628can be configured to be selectively engaged with the intermediate firingshaft portion 1602 of the firing member assembly 1600. Moreparticularly, when the lock sleeve 1622 is in its engaged position, thelock protrusions 1626, 1628 are positioned within a drive notch 1605defined in the intermediate firing shaft portion 1602 such that a distalpushing force and/or a proximal pulling force can be transmitted fromthe firing member assembly 1600 to the lock sleeve 1622. When the locksleeve 1622 is in its engaged position, the second lock member 1629 isreceived within a drive notch 1704 defined in the articulation driver1700 such that the distal pushing force and/or the proximal pullingforce applied to the lock sleeve 1622 can be transmitted to thearticulation driver 1700. In effect, the firing member assembly 1600,the lock sleeve 1622, and the articulation driver 1700 will movetogether when the lock sleeve 1622 is in its engaged position. On theother hand, when the lock sleeve 1622 is in its disengaged position, thelock protrusions 1626, 1628 may not be positioned within the drive notch1605 of the intermediate firing shaft portion 1602 of the firing memberassembly 1600 and, as a result, a distal pushing force and/or a proximalpulling force may not be transmitted from the firing member assembly1600 to the lock sleeve 1622.

Correspondingly, the distal pushing force and/or the proximal pullingforce may not be transmitted to the articulation driver 1700. In suchcircumstances, the firing member assembly 1600 can be slid proximallyand/or distally relative to the lock sleeve 1622 and the proximalarticulation driver 1700. The clutching assembly 1620 further includes aswitch drum 1630 that interfaces with the lock sleeve 1622. Furtherdetails concerning the operation of the switch drum and lock sleeve 1622may be found in U.S. patent application Ser. No. 13/803,086, now U.S.Patent Application Publication No. 2014/0263541, and Ser. No.15/019,196. The switch drum 1630 can further comprise at least partiallycircumferential openings 1632, 1634 defined therein which can receivecircumferential mounts 1305 that extend from the nozzle halves 1302,1304 and permit relative rotation, but not translation, between theswitch drum 1630 and the proximal nozzle 1300. See FIG. 6. Rotation ofthe nozzle 1300 to a point where the mounts reach the end of theirrespective slots 1632, 1634 in the switch drum 1630 will result inrotation of the switch drum 1630 about the shaft axis SA. Rotation ofthe switch drum 1630 will ultimately result in the movement of the locksleeve 1622 between its engaged and disengaged positions. Thus, inessence, the nozzle 1300 may be employed to operably engage anddisengage the articulation drive system with the firing drive system inthe various manners described in further detail in U.S. patentapplication Ser. No. 13/803,086, now U.S. Patent Application PublicationNo. 2014/0263541, and U.S. patent application Ser. No. 15/019,196, whichhave each been herein incorporated by reference in their respectiveentirety.

In the illustrated arrangement, the switch drum 1630 includes a anL-shaped slot 1636 that extends into a distal opening 1637 in the switchdrum 1630. The distal opening 1637 receives a transverse pin 1639 of ashifter plate 1638. In one example, the shifter plate 1638 is receivedwithin a longitudinal slot that is provided in the lock sleeve 1622 tofacilitate the axial movement of the lock sleeve 1622 when engaged withthe articulation driver 1700. Further details regarding the operation ofthe shifter plate and shift drum arrangements may be found in U.S.patent application Ser. No. 14/868,718, filed Sep. 28, 2015, entitledSURGICAL STAPLING INSTRUMENT WITH SHAFT RELEASE, POWERED FIRING ANDPOWERED ARTICULATION, now U.S. Patent Application Publication No.2017/0086823, the entire disclosure of which is hereby incorporated byreference herein.

As also illustrated in FIGS. 7 and 8, the interchangeable tool assembly1000 can comprise a slip ring assembly 1640 which can be configured toconduct electrical power to and/or from the end effector 1100, and/orcommunicate signals to and/or from the end effector 1100, back to amicroprocessor in the handle assembly or robotic system controller, forexample. Further details concerning the slip ring assembly 1640 andassociated connectors may be found in U.S. patent application Ser. No.13/803,086, now U.S. Patent Application Publication No. 2014/0263541,and U.S. patent application Ser. No. 15/019,196 which have each beenherein incorporated by reference in their respective entirety as well asin U.S. patent application Ser. No. 13/800,067, entitled STAPLECARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, now U.S. Patent ApplicationPublication No. 2014/0263552, which is hereby incorporated by referenceherein in its entirety. As also described in further detail in theaforementioned patent applications that have been incorporated byreference herein, the interchangeable surgical tool assembly 1000 canalso comprise at least one sensor that is configured to detect theposition of the switch drum 1630.

Referring again to FIG. 7, the chassis 1800 includes one or more taperedattachment portions 1802 formed thereon that are adapted to be receivedwithin corresponding dovetail slots 507 formed within the distal endportion of the frame 506 of the handle assembly 500 as was discussedabove. As can be further seen in FIG. 7, a shaft attachment lug 1605 isformed on the proximal end of the intermediate firing shaft 1602. Aswill be discussed in further detail below, the shaft attachment lug 1605is received in a firing shaft attachment cradle 542 that is formed inthe distal end of the longitudinal drive member 540 when theinterchangeable surgical tool assembly 1000 is coupled to the handleassembly 500. See FIG. 3.

Various interchangeable surgical tool assemblies employ a latch system1810 for removably coupling the interchangeable surgical tool assembly1000 to the frame 506 of the handle assembly 500. In at least one form,as can be seen in FIG. 7, the latch system 1810 includes a lock memberor lock yoke 1812 that is movably coupled to the chassis 1800. The lockyoke 1812 has a U-shape with two spaced downwardly extending legs 1814.The legs 1814 each have a pivot lug formed thereon that are adapted tobe received in corresponding holes 1816 formed in the chassis 1800. Suchan arrangement facilitates the pivotal attachment of the lock yoke 1812to the chassis 1800. The lock yoke 1812 may include two proximallyprotruding lock lugs 1818 that are configured for releasable engagementwith corresponding lock detents or grooves 509 in the distal end of theframe 506 of the handle assembly 500. See FIG. 3. In various forms, thelock yoke 1812 is biased in the proximal direction by a spring orbiasing member 1819. Actuation of the lock yoke 1812 may be accomplishedby a latch button 1820 that is slidably mounted on a latch actuatorassembly 1822 that is mounted to the chassis 1800. The latch button 1820may be biased in a proximal direction relative to the lock yoke 1812.The lock yoke 1812 may be moved to an unlocked position by biasing thelatch button 1820 the in distal direction which also causes the lockyoke 1812 to pivot out of retaining engagement with the distal end ofthe frame 506. When the lock yoke 1812 is in retaining engagement withthe distal end of the frame 506, the lock lugs 1818 are retaininglyseated within the corresponding lock detents or grooves 509 in thedistal end of the frame 506.

In the illustrated arrangement, the lock yoke 1812 includes at least oneand preferably two lock hooks 1824 that are adapted to contactcorresponding lock lug portions 1426 that are formed on the closureshuttle 1420. When the closure shuttle 1420 is in an unactuatedposition, the lock yoke 1812 may be pivoted in a distal direction tounlock the interchangeable surgical tool assembly 1000 from the handleassembly 500. When in that position, the lock hooks 1824 do not contactthe lock lug portions 1426 on the closure shuttle 1420. However, whenthe closure shuttle 1420 is moved to an actuated position, the lock yoke1812 is prevented from being pivoted to an unlocked position. Statedanother way, if the clinician were to attempt to pivot the lock yoke1812 to an unlocked position or, for example, the lock yoke 1812 was inadvertently bumped or contacted in a manner that might otherwise causeit to pivot distally, the lock hooks 1824 on the lock yoke 1812 willcontact the lock lugs 1426 on the closure shuttle 1420 and preventmovement of the lock yoke 1812 to an unlocked position.

Still referring to FIG. 10, the knife bar 1610 may comprise a laminatedbeam structure that includes at least two beam layers. Such beam layersmay comprise, for example, stainless steel bands that are interconnectedby, for example, welds and/or pins at their proximal ends and/or atother locations along the length of the bands. In alternativeembodiments, the distal ends of the bands are not connected together toallow the laminates or bands to splay relative to each other when theend effector is articulated. Such an arrangement permits the knife bar1610 to be sufficiently flexible to accommodate articulation of the endeffector. Various laminated knife bar arrangements are disclosed in U.S.patent application Ser. No. 15/019,245. As can also be seen in FIG. 10,a middle support member 1614 is employed to provide lateral support tothe knife bar 1610 as it flexes to accommodate articulation of thesurgical end effector 1100. Further details concerning the middlesupport member and alternative knife bar support arrangements aredisclosed in U.S. patent application Ser. No. 15/019,245. As can also beseen in FIG. 10, a firing member or knife member 1620 is attached to thedistal end of the knife bar 1610.

FIG. 11 illustrates one form of a firing member 1660 that may beemployed with the interchangeable tool assembly 1000. The firing member1660 comprises a body portion 1662 that includes a proximally extendingconnector member 1663 that is configured to be received in acorrespondingly shaped connector opening 1614 in the distal end of theknife bar 1610. See FIG. 10. The connector 1663 may be retained withinthe connector opening 1614 by friction, welding, and/or a suitableadhesive, for example. Referring to FIGS. 15-17, the body portion 1662protrudes through an elongate slot 1104 in the elongate channel 1102 andterminates in a foot member 1664 that extends laterally on each side ofthe body portion 1662. As the firing member 1660 is driven distallythrough the surgical staple cartridge 1110, the foot member 1664 rideswithin a passage in the elongate channel 1102 that is located under thesurgical staple cartridge 1110. As can be seen in FIG. 11, the firingmember 1660 may further include laterally protruding central tabs, pins,or retainer features 1680. As the firing member 1660 is driven distallythrough the surgical staple cartridge 1110, the central retainerfeatures 1680 ride on the inner surface 1106 of the elongate channel1102. The body portion 1662 of the firing member 1660 further includes atissue cutting edge or feature 1666 that is disposed between a distallyprotruding shoulder 1665 and a distally protruding top nose portion1670. As can be further seen in FIG. 11, the firing member 1660 mayfurther include two laterally extending top tabs, pins or anvilengagement features 1665. See FIGS. 13 and 14. As the firing member 1660is driven distally, a top portion of the body 1662 extends through acentrally disposed anvil slot 1138 (FIG. 14) and the top anvilengagement features 1672 ride on corresponding ledges 1136 formed oneach side of the anvil slot 1134.

Returning to FIG. 10, the firing member 1660 is configured to operablyinterface with a sled 1120 that is supported within the body 1111 of thesurgical staple cartridge 1110. The sled 1120 is slidably displaceablewithin the surgical staple cartridge body 1111 from a proximal startingposition adjacent the proximal end 1112 of the cartridge body 1111 to anending position adjacent a distal end 1113 of the cartridge body 1111.The cartridge body 1111 operably supports therein a plurality of stapledrivers (not shown in FIG. 10) that are aligned in rows on each side ofa centrally disposed slot 1114. The centrally disposed slot 1114 enablesthe firing member 1660 to pass therethrough and cut the tissue that isclamped between the anvil 1130 and the staple cartridge 1110. Thedrivers are associated with corresponding pockets 1115 that open throughthe upper deck surface of the cartridge body. Each of the staple driverssupports one or more surgical staples or fasteners thereon. The sled1120 includes a plurality of sloped or wedge-shaped cams 1122 whereineach cam 1122 corresponds to a particular line of fasteners or driverslocated on a side of the slot 1114. In the illustrated example, one cam1122 is aligned with one line of “double” drivers that each support twostaples or fasteners thereon and another cam 1122 is aligned withanother line of “single” drivers on the same side of the slot 1114 thateach support a single surgical staple or fastener thereon. Thus, in theillustrated example, when the surgical staple cartridge 1110 is “fired”,there will be three lines of staples on each lateral side of the tissuecut line. However, other cartridge and driver configurations could alsobe employed to fire other staple/fastener arrangements. The sled 1120has a central body portion 1124 that is configured to be engaged by theshoulder 1665 of the firing member 1660. When the firing member 1660 isfired or driven distally, the firing member 1660 drives the sled 1120distally as well. As the firing member 1660 moves distally through thecartridge 1110, the tissue cutting feature 1666 cuts the tissue that isclamped between the anvil assembly 1130 and the cartridge 1110 and,also, the sled 1120 drives the drivers upwardly in the cartridge whichdrive the corresponding staples or fasteners into forming contact withthe anvil assembly 1130.

In embodiments where the firing member includes a tissue cuttingsurface, it may be desirable for the elongate shaft assembly to beconfigured in such a way so as to prevent the inadvertent advancement ofthe firing member unless an unspent staple cartridge is properlysupported in the elongate channel 1102 of the surgical end effector1100. If, for example, no staple cartridge is present at all and thefiring member is distally advanced through the end effector, the tissuewould be severed, but not stapled. Similarly, if a spent staplecartridge (i.e., a staple cartridge wherein at least some of the stapleshave already been fired therefrom) is present in the end effector andthe firing member is advanced, the tissue would be severed, but may notbe completely stapled, if at all. It will be appreciated that suchoccurrences could lead to undesirable results during the surgicalprocedure. U.S. Pat. No. 6,988,649 entitled SURGICAL STAPLING INSTRUMENTHAVING A SPENT CARTRIDGE LOCKOUT, U.S. Pat. No. 7,044,352 entitledSURGICAL STAPLING INSTRUMENT HAVING A SINGLE LOCKOUT MECHANISM FORPREVENTION OF FIRING, and U.S. Pat. No. 7,380,695 entitled SURGICALSTAPLING INSTRUMENT HAVING A SINGLE LOCKOUT MECHANISM FOR PREVENTION OFFIRING, and U.S. patent application Ser. No. 14/742,933, entitledSURGICAL STAPLING INSTRUMENTS WITH LOCKOUT ARRANGEMENTS FOR PREVENTINGFIRING SYSTEM ACTUATION WHEN A CARTRIDGE IS SPENT OR MISSING eachdisclose various firing member lockout arrangements. Each of thosereferences is hereby incorporated by reference in its entirety herein.

An “unfired”, “unspent”, “fresh” or “new” fastener cartridge 1110 meansthat the fastener cartridge 1110 has all of its fasteners in their“ready-to-be-fired positions”. The new cartridge 1110 is seated withinthe elongate channel 1102 and may be retained therein by snap featureson the cartridge body that are configured to retainingly engagecorresponding portions of the elongate channel 1102. FIGS. 15 and 18illustrate a portion of the surgical end effector 1100 with a new orunfired surgical staple cartridge 1110 seated therein. As can be seen inFIGS. 15 and 18, the sled 1120 is in its starting position. To preventthe firing system from being activated and, more precisely, to preventthe firing member 1660 from being distally driven through the endeffector 1110 unless an unfired or new surgical staple cartridge hasbeen properly seated within the elongate channel 1102, theinterchangeable surgical tool assembly 1000 employs a firing memberlockout system generally designated as 1650.

Referring now to FIGS. 10 and 15-19, the firing member lockout system1650 includes a movable lock member 1652 that is configured toretainingly engage the firing member 1660 when a new surgical staplecartridge 1110 is not seated properly within the elongate channel 1102.More specifically, the lock member 1652 comprises at least one laterallymoving locking portion 1654 that is configured to retainingly engage acorresponding portion of the firing member 1660 when the sled 1120 isnot present within the cartridge 1110 in its starting position. In fact,the lock member 1652 employs two laterally moving locking portions 1654which each engage a laterally extending portion of the firing member1660. Other lockout arrangements can be used.

The lock member 1652 comprises a generally U-shaped spring member whereeach laterally movable leg or locking portion 1654 extends from acentral spring portion 1653 and is configured to move in lateraldirections represented by “L” in FIGS. 18 and 19. It will be appreciatedthat the term “lateral directions” refers to directions that aretransverse to the shaft axis SA (FIG. 2). The spring or lock member 1652may be fabricated from high strength spring steel and/or a similarmaterial, for example. The central spring portion 1653 is seated withina slot 1236 in the end effector mounting assembly 1230. See FIG. 10. Ascan be seen in FIGS. 15-17, each of the laterally movable legs orlocking portions 1654 has a distal end 1656 with a locking window 1658therein. When the locking member 1652 is in a locked position, thecentral retainer feature 1680 on each lateral side of the firing member1660 extends into corresponding locking windows 1658 defined in thelocking portions 1654 to retainingly prevent the firing member frombeing distally, or axially, advanced.

Operation of the firing member lock out system will be explained withreference to FIGS. 15-19. FIGS. 15 and 18 illustrate a portion of thesurgical end effector 1100 with a new unfired cartridge 1110 properlyinstalled therein. As can be seen in FIGS. 15 and 18, the sled 1120includes an unlocking feature 1126 that corresponds to each of thelaterally movable locking portions 1654. An unlocking feature 1126 isprovided on or extends proximally from each of the central wedge-shapedcams 1122. In alternative arrangements, the unlocking feature 1126 maycomprise a proximally protruding portion of the correspondingwedge-shaped cam 1122. As can be seen in FIG. 18, the unlocking features1124 engage and bias the corresponding locking portions 1654 laterallyin a direction that is transverse to the shaft axis SA (FIG. 2) when thesled 1120 is in its starting position. When the locking portions 1654are in such unlocked orientations, the central retainer features 1680are not in retaining engagement with the locking windows 1658. In suchinstances, the firing member 1660 may be distally, or axially, advanced(fired). However, when a cartridge is not present in the elongatechannel 1102 or the sled 1120 has been moved out of its startingposition (meaning the cartridge is partially or completely fired), thelocking portions 1654 spring laterally into retaining engagement withthe firing member 1660. In such instances, referring to FIG. 19, thefiring member 1660 cannot be moved distally.

FIGS. 16 and 17 illustrate the retraction of the firing member 1660 backto its starting, or unfired, position after performing a staple firingstroke as discussed above. FIG. 16 depicts the initial reengagement ofthe retaining features 1680 into their corresponding locking windows1658. FIG. 17 illustrates the retaining feature in its locked positionwhen the firing member 1660 has been fully retracted back to itsstarting position. To assist in the lateral displacement of the lockingportions 1654 when they are contacted by the proximally moving retainingfeatures 1680, each of the retaining features 1680 may be provided witha proximally-facing, laterally-tapered end portion. Such a lockoutsystem prevents the actuation of the firing member 1660 when a newunfired cartridge is not present or when a new unfired cartridge ispresent, but has not been properly seated in the elongate channel 1102.In addition, the lockout system may prevent the clinician from distallyadvancing the firing member in the case where a spent or partially firedcartridge has been inadvertently properly seated within the elongatechannel. Another advantage that may be provided by the lockout system1650 is that, unlike other firing member lock out arrangements thatrequire movement of the firing member into and out of alignment with thecorresponding slots/passages in the staple cartridge, the firing member1660 remains in alignment with the cartridge passages while in thelocked and unlocked positions. The locking portions 1654 are designed tomove laterally into and out of engagement with corresponding sides ofthe firing member. Such lateral movement of the locking portions orportion is distinguishable from other locking arrangements that move invertical directions to engage and disengage portions of the firingmember.

Returning to FIGS. 13 and 14, the anvil 1130 includes an elongate anvilbody portion 1132 and a proximal anvil mounting portion 1150. Theelongate anvil body portion 1132 includes an outer surface 1134 thatdefines two downwardly extending tissue stop members 1136 that areadjacent to the proximal anvil mounting portion 1150. The elongate anvilbody portion 1132 also includes an underside 1135 that defines anelongate anvil slot 1138. In the illustrated arrangement shown in FIG.14, the anvil slot 1138 is centrally disposed in the underside 1135. Theunderside 1135 includes three rows 1140, 1141, 1142 of staple formingpockets 1143, 1144 and 1145 located on each side of the anvil slot 1138.Adjacent each side of the anvil slot 1138 are two elongate anvilpassages 1146. Each passage 1146 has a proximal ramp portion 1148. SeeFIG. 13. As the firing member 1660 is advanced distally, the top anvilengagement features 1632 initially enter the corresponding proximal rampportions 1148 and into the corresponding elongate anvil passages 1146.

Turning to FIGS. 12 and 13, the anvil slot 1138, as well as the proximalramp portion 1148, extend into the anvil mounting portion 1150. Statedanother way, the anvil slot 1138 divides or bifurcates the anvilmounting portion 1150 into two anvil attachment flanges 1151. The anvilattachments flanges 1151 are coupled together at their proximal ends bya connection bridge 1153. The connection bridge 1153 supports the anvilattachment flanges 1151 and can serve to make the anvil mounting portion1150 more rigid than the mounting portions of other anvil arrangementswhich are not connected at their proximal ends. As can also be seen inFIGS. 12 and 14, the anvil slot 1138 has a wide portion 1139 toaccommodate the top portion including the top anvil engagement features1632, of the firing member 1660 when the firing member 1660 is in itsproximal unfired position.

As can be seen in FIGS. 13 and 20-24, each of the anvil attachmentflanges 1151 includes a transverse mounting hole 1156 that is configuredto receive a pivot pin 1158 (FIGS. 10 and 20) therethrough. The anvilmounting portion 1150 is pivotally pinned to the proximal end 1103 ofthe elongate channel 1102 by the pivot pin 1158 which extends throughmounting holes 1107 in the proximal end 1103 of the elongate channel1102 and the mounting hole 1156 in anvil mounting portion 1150. Such anarrangement pivotally affixes the anvil 1130 to the elongate channel1102 s that the anvil 1130 can be pivoted about a fixed anvil axis A-Awhich is transverse to the shaft axis SA. See FIG. 5. The anvil mountingportion 1150 also includes a cam surface 1152 that extends from acentralized firing member parking area 1154 to the outer surface 1134 ofthe anvil body portion 1132.

Further to the above, the anvil 1130 is movable between an open positionand closed positions by axially advancing and retracting the distalclosure tube segment 1430, as discussed further below. A distal endportion of the distal closure tube segment 1430 has an internal camsurface formed thereon that is configured to engage the cam surface1552, or cam surfaces formed on the anvil mounting portion 1150, andmove the anvil 1130. FIG. 22 illustrates a cam surface 1152 a formed onthe anvil mounting portion 1150 so as to establish a single contact path1155 a with the internal cam surface 1444, for example, on the distalclosure tube segment 1430. FIG. 23 illustrates a cam surface 1152 b thatis configured relative to the internal cam surface 1444 on the distalclosure tube segment to establish two separate and distinct arcuatecontact paths 1155 b between the cam surface 1152 on the anvil mountingportion 1150 and internal cam surface 1444 on the distal closure tubesegment 1430. In addition to other potential advantages discussedherein, such an arrangement may better distribute the closure forcesfrom the distal closure tube segment 1430 to the anvil 1130. FIG. 24illustrates a cam surface 1152 c that is configured relative to theinternal cam surface 1444 of the distal closure tube segment 1430 toestablish three distinct zones of contact 1155 c and 1155 d between thecam surfaces on the anvil mounting portion 1150 and the distal closuretube segment 1430. The zones 1155 c, 1155 d establish larger areas ofcamming contact between the cam surface or cam surfaces on the distalclosure tube segment 1430 and the anvil mounting portion 1150 and maybetter distribute the closure forces to the anvil 1130.

As the distal closure tube segment 1430 cammingly engages the anvilmounting portion 1150 of the anvil 1130, the anvil 1130 is pivoted aboutthe anvil axis AA (FIG. 5) which results in the pivotal movement of thedistal end of the end 1133 of elongate anvil body portion 1132 towardthe surgical staple cartridge 1110 and the distal end 1105 of theelongate channel 1102. As the anvil body portion 1132 begins to pivot,it contacts the tissue that is to be cut and stapled which is nowpositioned between the underside 1135 of the elongate anvil body portion1132 and the deck 1116 of the surgical staple cartridge 1110. As theanvil body portion 1132 is compressed onto the tissue, the anvil 1130may experience considerable amounts of resistive forces and/or bendingloads, for example. These resistive forces are overcome as the distalclosure tube 1430 continues its distal advancement. However, dependingupon their magnitudes and points of application to the anvil bodyportion 1132, these resistive forces could tend to cause portions of theanvil 1130 to flex away from the staple cartridge 1110 which maygenerally be undesirable. For example, such flexure may causemisalignment between the firing member 1660 and the passages 1148, 1146within the anvil 1130. In instances wherein the flexure is excessive,such flexure could significantly increase the amount of firing forcerequired to fire the instrument (i.e., drive the firing member 1660through the tissue from its starting to ending position). Such excessivefiring force may result in damage to the end effector, the firingmember, the knife bar, and/or the firing drive system components, forexample. Thus, it may be advantageous for the anvil to be constructed soas to resist such flexure.

FIGS. 25-27 illustrate an anvil 1130′ that includes features thatimprove the stiffness of the anvil body and its resistance to flexureforces that may be generated during the closing and/or firing processes.The anvil 1130′ may otherwise be identical in construction to the anvil1130 described above except for the differences discussed herein. As canbe seen in FIGS. 25-27, the anvil 1130′ has an elongate anvil body 1132′that has an upper body portion 1165 that and anvil cap 1170 attachedthereto. The anvil cap 1170 is roughly rectangular in shape and has anouter cap perimeter 1172, although the anvil cap 1170 can have anysuitable shape. The perimeter 1172 of the anvil cap 1170 is configuredto be inserted into a correspondingly-shaped opening 1137 formed in theupper body portion 1165 and positioned against axially extendinginternal ledge portions 1139 formed therein. See FIG. 27. The internalledge portions 1139 are configured to support the corresponding longsides 1177 of the anvil cap 1170. In an alternative embodiment, theanvil cap 1170 may be slid onto the internal ledges 1139 through anopening in the distal end 1133 of the anvil body 1132′. In yet anotherembodiment, no internal ledge portions are provided. The anvil body1132′ and the anvil cap 1170 may be fabricated from suitable metal thatis conducive to welding. A first weld 1178 may extend around the entirecap perimeter 1172 of the anvil cap 1170 or it may only be located alongthe long sides 1177 of the anvil cap 1170 and not the distal end 1173and/or proximal end 1175 thereof. The first weld 1178 may be continuousor it may be discontinuous or intermittent. In those embodiments wherethe first weld 1178 is discontinuous or intermittent, the weld segmentsmay be equally distributed along the long sides 1177 of the anvil cap1170, more densely spaced closer to the distal ends of the long sides1177, and/or more densely spaced closer to the proximal ends of the longsides 1177. In certain arrangements, the weld segments may be moredensely spaced in the center areas of the long sides 1177 of the anvilcap 1170.

FIGS. 28-30 illustrate an anvil cap 1170′ that is configured to bemechanically interlocked to the anvil body 1132′ as well as welded tothe upper body portion 1165. In this embodiment, a plurality ofretention formations 1182 are defined in the wall 1180 of the upper bodyportion 1165 that defines opening 1137. As used in this context, theterm “mechanically interlocked” means that the anvil cap will remainaffixed to the elongate anvil body regardless of the orientation of theelongate anvil body and without any additional retaining or fasteningsuch as welding and/or adhesive, for example. The retention formations1182 may protrude inwardly into the opening 1137 from the opening wall1180, although any suitable arrangement can be used. The retentionformations 1182 may be integrally formed into the wall 1180 or otherwisebe attached thereto. The retention formations 1182 are designed tofrictionally engage a corresponding portion of the anvil cap 1170′ whenthe anvil cap 1170′ is installed in the opening 1137 to frictionallyretain the anvil cap 1170′ therein. The retention formations 1182protrude inwardly into the opening 1137 and are configured to befrictionally received within a correspondingly shaped engagement area1184 formed in the outer perimeter 1172′ of the anvil cap 1170′. Theretention formations 1182 only correspond to the long sides 1177′ of theanvil cap 1170′ and are not provided in the portions of the wall 1180that correspond to the distal end 1173 or proximal end 1175 of the anvilcap 1170′. In alternative arrangements, the retention formations 1182may also be provided in the portions of the wall 1180 that correspond tothe distal end 1173 and proximal end 1175 of the anvil cap 1170′ as wellas the long sides 1177′ thereof. In still other arrangements, theretention formations 1182 may only be provided in the portions of thewall 1180 that correspond to one or both of the distal and proximal ends1173, 1175 of the anvil cap 1170′. In still other arrangements, theretention formations 1182 may be provided in the portions of the wall1180 corresponding to the long sides 1177′ and only one of the proximaland distal ends 1173, 1175 of the anvil cap 1170′. It will be furtherunderstood that the retention protrusions in all of the foregoingembodiments may be alternatively formed on the anvil cap with theengagement areas being formed in the elongate anvil body.

In the embodiment illustrated in FIGS. 28-30, the retention formations1182 are equally spaced or equally distributed along the wall portions1180 of the anvil cap 1170′. In alternative embodiments, the retentionformations 1182 may be more densely spaced closer to the distal ends ofthe long sides 1177′ or more densely spaced closer to the proximal endsof the long sides 1177′. Stated another way, the spacing between thoseretention formations adjacent the distal end, the proximal end or boththe distal and proximal ends may be less than the spacing of theformations located in the central portion of the anvil cap 1170′. Instill other arrangements, the retention formations 1182 may be moredensely spaced in the center areas of the long sides 1177′ of the anvilcap 1170′. In some alternative embodiments, the correspondingly shapedengagement areas 1184 may not be provided in the outer perimeter 1172′or in portions of the outer perimeter 1172′ of the anvil cap 1170′. Inother embodiments, the retention formations and correspondingly-shapedengagement areas may be provided with different shapes and sizes. Inalternative arrangements, the retention formations may be sized relativeto the engagement areas so that there is no interference fittherebetween. In such arrangements, the anvil cap may be retained inposition by welding, and/or an adhesive, for example.

In the illustrated example, a weld 1178′ extends around the entireperimeter 1172′ of the anvil cap 1170′. Alternatively, the weld 1178′ islocated along the long sides 1177′ of the anvil cap 1170′ and not thedistal end 1173 and/or proximal end 1175 thereof. The weld 1178′ may becontinuous or it may be discontinuous or intermittent. In thoseembodiments where the weld 1178′ is discontinuous or intermittent, theweld segments may be equally distributed along the long sides 1177′ ofthe anvil cap 1170′ or the weld segments may be more densely spacedcloser to the distal ends of the long sides 1177′ or more densely spacedcloser to the proximal ends of the long sides 1177′. In still otherarrangements, the weld segments may be more densely spaced in the centerareas of the long sides 1177′ of the anvil cap 1170′.

FIGS. 31 and 32 illustrate another anvil arrangement 1130″ that has ananvil cap 1170″ attached thereto. The anvil cap 1170″ is roughlyrectangular in shape and has an outer cap perimeter 1172″; however, theanvil cap 1170″ can comprise of any suitable configuration. The outercap perimeter 1172″ is configured to be inserted into acorrespondingly-shaped opening 1137″ in upper body portion 1165 of theanvil body 1132″ and received on axially extending internal ledgeportions 1139″ and 1190″ formed therein. See FIG. 32. The ledge portions1139″ and 1190″ are configured to support the corresponding long sides1177″ of the anvil cap 1170″. In an alternative embodiment, the anvilcap 1170″ is slid onto the internal ledges 1139″ and 1190″ through anopening in the distal end 1133″ of the anvil body 1132′. The anvil body1132″ and the anvil cap 1170″ may be fabricated from metal material thatis conducive to welding. A first weld 1178″ may extend around the entireperimeter 1172″ of the anvil cap 1170″ or it may only be located alongthe long sides 1177″ of the anvil cap 1170″ and not the distal end 1173″and/or proximal end thereof. The weld 1178″ may be continuous or it maybe discontinuous or intermittent. It will be appreciated that thecontinuous weld embodiment has more weld surface area due to theirregularly shape perimeter of the anvil cap 1170″ as compared to theembodiments with a straight perimeter sides such as the anvil caps shownin FIG. 26, for example. In those embodiments where the weld 1178″ isdiscontinuous or intermittent, the weld segments may be equallydistributed along the long sides 1177″ of the anvil cap 1170″ or theweld segments may be more densely spaced closer to the distal ends ofthe long sides 1177″ or more densely spaced closer to the proximal endsof the long sides 1177″. In still other arrangements, the weld segmentsmay be more densely spaced in the center areas of the long sides 1177″of the anvil cap 1170″.

Still referring to FIGS. 31 and 32, the anvil cap 1170″ may beadditionally welded to the anvil body 1132″ by a plurality of seconddiscrete “deep” welds 1192″. For example, each weld 1192″ may be placedat the bottom of a corresponding hole or opening 1194″ provided throughthe anvil cap 1170″ so that a discrete weld 1192″ may be formed alongthe portion of the anvil body 1132″ between the ledges 1190″ and 1139″.See FIG. 32. The welds 1192″ may be equally distributed along the longsides 1177″ of the anvil cap 1170″ or the welds 1192″ may be moredensely spaced closer to the distal ends of the long sides 1177″ or moredensely spaced closer to the proximal ends of the long sides 1177″. Instill other arrangements, the welds 1192″ may be more densely spaced inthe center areas of the long sides 1177″ of the anvil cap 1170″.

FIG. 33 illustrates another anvil cap 1170′″ that is configured to bemechanically interlocked to the anvil body 1132′″ as well as welded tothe upper body portion 1165. In this embodiment, a tongue-and-groovearrangement is employed along each long side 1177′″ of the anvil cap1170′″. In particular, a laterally extending continuous or intermittenttab 1195′″ protrudes from each of the long sides 1177′″ of the anvil cap1170′″. Each tab 1195′″ corresponds to an axial slot 1197′″ formed inthe anvil body 1132′″. The anvil cap 1170′″ is slid in from an openingin the distal end of the anvil body 1132′″ to “mechanically” affix theanvil cap to the anvil body 1132′″. The tabs 1195′″ and slots 1197′″ maybe sized relative to each other to establish a sliding frictional fittherebetween. In addition, the anvil cap 1170′″ may be welded to theanvil body 1132′″. The anvil body 1132′″ and the anvil cap 1170′″ may befabricated from metal that is conducive to welding. The weld 1178′″ mayextend around the entire perimeter 1172′″ of the anvil cap 1170′″ or itmay only be located along the long sides 1177′″ of the anvil cap 1170′″.The weld 1178′″ may be continuous or it may be discontinuous orintermittent. In those embodiments where the weld 1178′″ isdiscontinuous or intermittent, the weld segments may be equallydistributed along the long sides 1177′″ of the anvil cap 1170′″ or theweld segments may be more densely spaced closer to the distal ends ofthe long sides 1177′″ or more densely spaced closer to the proximal endsof the long sides 1177′″. In still other arrangements, the weld segmentsmay be more densely spaced in the center areas of the long sides 1177′″of the anvil cap 1170′″.

The anvil embodiments described herein with anvil caps may provideseveral advantages. One advantage for example, may make the anvil andfiring member assembly process easier. That is, the firing member may beinstalled through the opening in the anvil body while the anvil isattached to the elongate channel. Another advantage is that the uppercap may improve the anvil's stiffness and resistance to theabove-mentioned flexure forces that may be experienced when clampingtissue. By resisting such flexure, the frictional forces normallyencountered by the firing member 1660 may be reduced. Thus, the amountof firing force required to drive the firing member from its starting toending position in the surgical staple cartridge may also be reduced.

FIGS. 34-39 depict a forming pocket arrangement 10200 that is configuredto deform a staple during a surgical stapling procedure. The formingpocket arrangement 10200 and various alternative forming pocketarrangements are further described in U.S. patent application Ser. No.15/385,914, entitled METHOD OF DEFORMING STAPLES FROM TWO DIFFERENTTYPES OF STAPLE CARTRIDGES WITH THE SAME SURGICAL STAPLING INSTRUMENT,which was filed Dec. 21, 2016. U.S. patent application Ser. No.15/385,914 is incorporated by reference herein in its entirety. Theforming pocket arrangement 10200 comprises a proximal forming pocket10210 and a distal forming pocket 10230 defined in a planar, ortissue-engaging, surface 10207 of an anvil 10201. The pockets 10210,10230 are aligned along a longitudinal pocket axis 10203 of the formingpocket arrangement 10200. A staple is intended to be formed along thepocket axis 10203 by the forming pocket arrangement 10200 when deployedfrom a staple cartridge. Referring to FIGS. 35 and 36, the formingpocket arrangement 10200 further comprises a bridge portion 10205defined between the forming pockets 10210, 10230. In this instance, thebridge portion 10205 is recessed with respect to the planar surface10207 of the anvil 10201. The bridge portion 10205 comprises a bridgewidth “W” and a bridge depth “D”. The bridge depth “D” is the distancethat the bridge portion 10205 is recessed with respect to the planarsurface 10207. The forming pocket arrangement 10200 comprises a center“C” defined within the bridge portion 10205. The forming pocketarrangement 10200 is bilaterally symmetric with respect to the bridgeportion 10205, bilaterally symmetric with respect to pocket axis 10203,and rotationally symmetric with respect to the center “C”.

The forming pocket arrangement 10200 further comprises a pair of primarysidewalls 10208 extending from the planar surface 10207 of the anvil10201 toward the pockets 10210, 10230 and the bridge portion 10205. Theprimary sidewalls 10208 are angled at angle θ₂ (FIG. 37) with respect tothe planar surface 10207 of the anvil 10201. The forming pocketarrangement 10200 further comprises edge features 10215, 10235 whichprovide a transition feature between the outer edges of the pockets10210, 10230 and the planar surface 10207, between the longitudinaledges of the pockets 10210, 10230 and the primary sidewalls 10208, andbetween the inner edges of pockets 10210, 10230 and the bridge portion10205. These edges 10215, 10235 can be rounded, and/or chamfered, forexample. The edge features 10215, 10235 may help prevent staple tipsfrom sticking.

The forming pocket 10210 comprises a pair of pocket sidewalls 10213 andthe forming pocket 10230 comprises a pair of pocket sidewalls 10233. Thepocket sidewalls 10213, 10233 are configured to direct the staple tipsand the legs of the staples toward the forming surfaces of the pockets10210, 10230 in the event that the staple tips and/or the legs of thestaples initially strike the sidewalls 10213, 10233 of the pockets10210, 10230. The sidewalls 10213, 10233 extend from the transitionedges 10215, 10235 toward the forming surfaces of each pocket 10210,10230. The sidewalls 10213, 10233 of the forming pockets 10210, 10230are angled with respect to the planar surface 10207 of the anvil 10201at angle θ₁ (FIG. 38) in order to direct, or channel, the legs and/orthe staple tips of the staples toward the forming surfaces of thepockets 10210, 10230. The sidewalls 10213, 10233 are configured toencourage the staple tips and/or the legs of the staples to form alongthe pocket axis 10203 as the staples are formed against the formingsurfaces of the pockets 10210, 10230. Collectively, the primarysidewalls 10208 and the pocket sidewalls 10213, 10233 can provide afunnel-like configuration for directing staple tips. Referring to FIGS.37 and 38, the angle θ₁ is greater than the angle θ₂.

The pockets 10210, 10230 further comprise transition edges 10214, 10234which provide a transition feature between the pocket sidewalls 10213,10233 and the forming surfaces, as discussed in greater detail below. Invarious instances, the transition edges 10214, 10234 can comprise asimilar profile as the transition edges 10215, 10235. In otherinstances, the transition edges 10214, 10234 can comprise a differentprofile than the transition edges 10215, 10235. That said, the edges10214, 10234 can be rounded, or chamfered, for example. The edges 10214,10234 comprise a first end where the edges 10214, 10234 meet the outerends of the pockets 10210, 10230 and a second end where the edges 10214,10234 approach the bridge portion 10205, or the inner ends of thepockets 10210, 10230. The edges 10214, 10234 may transition into thetransition edges 10215, 10235 near the bridge portion 10205. The edgefeatures 10214, 10234 may also help prevent staple tips from sticking inthe pockets 10210, 10230 when forming.

Referring again to FIG. 35, the forming surfaces of the pockets 10210,10230 comprise an entry zone forming surface 10211, 10231 and an exitzone forming surface 10212, 10232, respectively. In this instance, theamount of surface area of the forming surfaces that the entry zoneforming surfaces 10211, 10231 cover is greater than the amount ofsurface area of the forming surfaces that the exit zone forming surfaces10212, 10232 cover. As a result, the entry zone forming surfaces 10211,10231 do not transition to the exit zone forming surfaces 10212, 10232in the center of each pocket 10210, 10230. Rather, the transition pointswhere the entry zones 10211, 10231 transition to the exit zones 10212,10232 are closer to the bridge portion 10205. The transitions betweenthe entry zone forming surfaces 10211, 10231 and the exit zone formingsurfaces 10212, 10232 define a valley, or trough of each pocket 10210,10230. The valleys of the forming pockets 10210, 10230 define a portion,or segment, of the forming surfaces having the greatest verticaldistance from the planar surface 10207.

Referring to FIG. 36, the forming surfaces of each pocket 10210, 10230comprise more than one radius of curvature. Specifically, the pocket10210 comprises an entry radius of curvature 10217 corresponding to theentry zone forming surface 10211 and an exit radius of curvature 10218corresponding to the exit zone forming surface 10212. Similarly, thepocket 10230 comprises an entry radius of curvature 10237 correspondingto the entry zone forming surface 10231 and an exit radius of curvature10238 corresponding to the exit zone forming surface 10232. In thisinstance, the entry radii of curvature 10217, 10237 are larger than theexit radii of curvature 10218, 10238, respectively. Specificrelationships between the radii of curvature and various pocket featuresalong with some potential advantages and patterns of the specificrelationships are further described in U.S. patent application Ser. No.15/385,914.

In addition to defining the transition points where the entry zonestransition to the exit zones, the valleys of the forming pockets 10210,10230 also define the narrowest portion of the forming surfaces of eachpocket 10210, 10230. The outer edges of each pocket 10210, 10230, alsoreferred to as entry edges because they define the beginning of theentry zone forming surfaces 10211, 10231, comprise an entry width. Theinner edges of each pocket 10210, 10230, also referred to as exit edgesbecause they define the end of the exit zone forming surfaces 10212,10232, comprise an exit width. In this instance, the entry width isgreater than the exit width. Also, the exit width is greater than thevalley width, or the narrowest portion of the forming surfaces. FIG. 38is a cross-sectional view of the distal forming pocket 10230 taken alongline 38-38 in FIG. 35. This view illustrates the valley, or trough, ofthe distal forming pocket 10230. This valley, or trough, is also thetransition between the entry zone forming surface 10231 and the exitzone forming surface 10232. FIG. 37 illustrates a cross-sectional viewof the distal forming pocket 10230 taken along line 37-37 in FIG. 35which is located within the exit zone forming surface 10232 of theforming pocket 10230. FIG. 39 is a cross-sectional view of the distalforming pocket 10230 taken along line 39-39 in FIG. 35 which is withinthe entry zone forming surface 10232 of the distal forming pocket 10230.

The forming pocket arrangement 10200, and various other forming pocketarrangements disclosed herein, are configured to be used with stapleswith various diameters. The diameters of staples to be used with theforming pocket arrangement 10200 can vary between about 0.0079 inchesand about 0.0094 inches, for example. Additionally, the entry radius ofcurvature and the exit radius of curvature of each forming surfacecomprise a ratio of about 1.5:1 to about 3:1 when the entry radius isbetween about 8× the staple diameter and 10× the staple diameter, forexample. In at least one instance, the entry radius of curvature and theexit radius of curvature of each forming surface comprise a ratio ofabout 2:1 when the entry radius is 9× the staple diameter, for example.In other instances, the entry radius of curvature and the exit radius ofcurvature of each forming surface comprise a ratio of about 1.5:1 toabout 3:1 when the entry radius is above about 0.6× the staple crownlength and the ridge, or bridge, width is less than 1× the staplediameter, for example. In at least one instance, the entry radius ofcurvature and the exit radius of curvature of each forming surfacecomprise a ratio of about 2:1 when the entry radius is above about 0.6×the staple crown length and the ridge, or bridge, width is less than 1×the staple diameter. The exit radius of curvature is between about 4×the staple diameter and about 6× diameter, for example. In at least oneinstance, the exit radius of curvature is about 4.5× the staplediameter.

FIGS. 40-45 depict a forming pocket arrangement 10500 that is configuredto deform a staple during a surgical stapling procedure. The formingpocket arrangement 10500 and various alternative forming pocketarrangements are further described in U.S. patent application Ser. No.15/385,914, entitled METHOD OF DEFORMING STAPLES FROM TWO DIFFERENTTYPES OF STAPLE CARTRIDGES WITH THE SAME SURGICAL STAPLING INSTRUMENT,which was filed Dec. 21, 2016. U.S. patent application Ser. No.15/385,914 is incorporated by reference herein in its entirety. Theforming pocket arrangement 10500 comprises a proximal forming pocket10510 and a distal forming pocket 10530 defined in a planar, ortissue-contacting, surface 10507 of an anvil 10501. The pockets 10510,10530 are aligned along a longitudinal pocket axis 10503 of the formingpocket arrangement 10500. A staple is intended to be formed along thepocket axis 10503 by the forming pocket arrangement 10500 when deployedfrom a staple cartridge. Referring to FIGS. 41 and 42, the formingpocket arrangement 10500 further comprises a bridge portion 10505defined between the forming pockets 10510, 10530. In this instance, thebridge portion 10505 is recessed with respect to the planar surface10507 of the anvil 10501. The bridge portion 10505 comprises a bridgewidth “W” and a bridge depth “D”. The bridge portion 10505 issubstantially V-shaped with a rounded bottom portion. The bridge depth“D” is the distance that the bottom portion of the bridge portion 10505is recessed with respect to the planar surface 10507. The forming pocketarrangement 10500 comprises a center “C” defined within the bridgeportion 10505. The forming pocket arrangement 10500 is bilaterallysymmetric with respect to the bridge portion 10505, bilaterallysymmetric with respect to pocket axis 10503, and rotationally symmetricwith respect to the center “C”.

The forming pocket arrangement 10500 further comprises a pair of primarysidewalls 10508 extending from the planar surface 10507 of the anvil10501 toward the pockets 10510, 10530 and the bridge portion 10505. Theprimary sidewalls 10508 are angled at angle θ₁ (FIG. 43) with respect tothe planar surface 10507 of the anvil 10501. The primary sidewalls 10508comprise inner edges that are curved, or contoured, with respect to thepockets 10510, 10530.

The forming pocket 10510 comprises a pair of pocket sidewalls 10513 andthe forming pocket 10530 comprises a pair of pocket sidewalls 10533. Thepocket sidewalls 10513, 10533 comprise curved, or contoured, profilesand are configured to direct the staple tips and the legs of the staplestoward the forming surfaces of the pockets 10510, 10530 as well as helpcontrol the forming process of the staples. The sidewalls 10513, 10533extend from the primary sidewalls 10508 and the planar surface 10507toward the forming surfaces of each pocket 10510, 10530. The sidewalls10513, 10533 are configured to encourage the staple tips and/or the legsof the staples to form along the pocket axis 10503 as the staples areformed against the forming surfaces of the pockets 10510, 10530.Collectively, the primary sidewalls 10508 and the pocket sidewalls10513, 10533 cooperate to funnel corresponding staple tips toward thelateral center of each pocket 10510, 10530. Discussed in greater detailbelow, the sidewalls 10513, 10533 comprise entry portions and exitportions where the entry portions comprise a less aggressive channelingconfiguration than the exit portions.

Referring again to FIG. 41, the forming surfaces of the pockets 10510,10530 comprise an entry zone forming surface 10511, 10531 and an exitzone forming surface 10512, 10532, respectively. The entry zone formingsurfaces 10511, 10531 coincide with the less aggressive channelingportions of the sidewalls 10513, 10533. Similarly, the exit zone formingsurfaces 10512, 10532 coincide with the more aggressive channelingportions of the sidewalls 10513, 10533. The pockets 10510, 10530 furthercomprise a forming, or guiding, groove 10515, 10535, also referred to asa tip control channel, extending the entire longitudinal length of eachpocket 10510, 10530 and positioned centrally with respect to the outerlateral edges of the pockets 10510, 10530. The grooves 10515, 10535 arenarrower at the outer longitudinal edges of the pockets 10510, 10530than the inner longitudinal edges of the pockets 10510, 10530. Thegrooves 10515, 10535 meet at the bridge portion 10505 to encourage thestaple tips, and staple legs, to contact each other during the formingprocess, as further discussed in U.S. patent application Ser. No.15/385,914. In some instances, grooves defined in the forming surfacesof forming pockets can have a similar effect in staple forming as moreaggressively-angled exit walls and/or narrowly-configured exit walls.

Referring to FIG. 42, the forming surfaces of each pocket 10510, 10530comprise more than one radius of curvature. Specifically, the pocket10510 comprises an entry radius of curvature 10517 corresponding to theentry zone forming surface 10511 and an exit radius of curvature 10518corresponding to the exit zone forming surface 10512. Similarly, thepocket 10530 comprises an entry radius of curvature 10537 correspondingto the entry zone forming surface 10531 and an exit radius of curvature10538 corresponding to the exit zone forming surface 10532. In thisinstance, the entry radii of curvature 10517, 10537 are larger than theexit radii of curvature 10518, 10538. Specific relationships between theradii of curvature and various pocket features along with some potentialadvantages and patterns of the specific relationships are furtherdescribed in U.S. patent application Ser. No. 15/385,914.

Referring now to FIGS. 43-45, the outer longitudinal edges of eachpocket 10510, 10530 are referred to as entry edges because they definethe beginning of the entry zone forming surfaces 10511, 10531. The entryedges comprise an entry width which is the largest width of the formingsurfaces of each pocket 10510, 10530. The inner edges of each pocket10510, 10530 are referred to as exit edges because they define the endof the exit zone forming surfaces 10512, 10532. The exit edges comprisean exit width, also referred to as the bridge width “W”, which is thenarrowest section of the forming surfaces of each pocket 10510, 10530.The transitions between entry and exit zones comprise a transition widthwhich is less than the entry width but greater than the exit width. FIG.44 is a cross-sectional view of the distal forming pocket 10530 takenalong line 44-44 in FIG. 41. This view is taken near the valley, ortrough, of the distal forming pocket 10530. This valley, or trough, isalso the transition between the entry zone forming surface 10531 and theexit zone forming surface 10532. In various instances, the transitionbetween entry and exit zones does not occur at the valley, or trough, ofthe pocket. FIG. 43 illustrates a cross-sectional view of the distalforming pocket 10530 taken along line 43-43 in FIG. 41 which is locatedwithin the exit zone forming surface 10532 of the forming pocket 10530.FIG. 45 is a cross-sectional view of the distal forming pocket 10530taken along line 45-45 in FIG. 41 which is within the entry zone formingsurface 10532 of the distal forming pocket 10530. The sidewalls 10533are illustrated in this figure as linear, or at least substantiallylinear, and are angled at angle θ₂ (FIG. 45) with respect to the planarsurface 10507. Angle θ₂ is greater than angle θ₁ (FIG. 43).

FIGS. 46 and 47 depict staples formed with the forming pocketarrangement 10500 where one staple was aligned with the pocket axis10503 of the forming pocket arrangement 10500 and the other staple wasmisaligned with the pocket axis 10503 of the forming pocket arrangement10500. FIG. 46 depicts a side view 13100 and a bottom view 13100′ of astaple 13101 in a fully-formed configuration formed with the formingpocket arrangement 10500. This staple 13101 was aligned with the pocketaxis 10503 of the forming pocket arrangement 10500 during the formingprocess. The tips 13104 of the staple legs 13103 struck the formingpocket arrangement 10500 along the pocket axis 10503.

The staple 13101 comprises a first tip alignment axis TA1, a second tipalignment axis TA2, and a crown alignment axis CA. When aligned with thepocket axis 10503, the staple 13101 forms such that the second tipalignment axis TA2 and the crown alignment axis CA are substantiallyaligned or, in other words, the staple 13101 assumes a substantiallyplanar configuration. The force to fire the staple 13101 is illustratedin the graph 13110.

FIG. 47 depicts a side view 13120 and a bottom view 13120′ of a staple13121 in a fully formed configuration formed with the forming pocketarrangement 10500. This staple 13121 was misaligned with the pocket axis10503 of the forming pocket arrangement 10500 during the formingprocess. The staple 13121 was driven off plane with respect to thepocket axis 10503. The tips 13124 of the staple legs 13123 did notstrike the forming pocket arrangement 10500 along the pocket axis 10503nor was the crown, or base, 13122 of the staple 13121 aligned with thepocket axis 10503 during forming.

The staple 13121 comprises a first tip alignment axis TA1, a second tipalignment axis TA2, and a crown alignment axis CA. When misaligned withthe pocket axis 10503, the staple 13121 forms such that the second tipalignment axis TA2 and the crown alignment axis CA are substantiallyaligned with each other or, in other words, the staple 13121 assumes asubstantially planar configuration. Compared to FIG. 46 where the staple13101 was aligned with the pocket axis 10503, the staple 13121 formsinto a fully-formed configuration that may be more acceptable to asurgeon to more adequately seal tissue than staples formed with otherforming pocket arrangements which form in a misaligned state.

FIGS. 48-54 depict a forming pocket arrangement 6500 that is configuredto deform a staple during a surgical stapling procedure. The formingpocket arrangement 6500 comprises a proximal forming cup, or pocket,6510 and a distal forming cup, or pocket, 6530 defined in a planar, ortissue-contacting, surface 6507 of an anvil 6501. The tissue-contactingsurface 6507 of the anvil 6501 can be configured to compress tissueagainst a staple cartridge when the anvil 6501 is clamped or closedrelative to the staple cartridge. Each cup 6510, 6530 is defined by aboundary surface as further described herein. The cups 6510, 6530 arealigned along a pocket axis 6503 of the forming pocket arrangement 6500.A staple is intended to be formed along the pocket axis 6503 by theforming pocket arrangement 6500 when deployed from a staple cartridge.For example, a first leg of the staple is formed by the proximal formingcup 6510 and a second leg of the staple is formed by the distal formingcup 6530. In such instances, the first leg of the staple is aligned witha portion of the proximal forming cup 6510 and the second leg of thestaple is aligned with a portion of the distal forming cup 6530 when theanvil 6501 is clamped relative to the staple cartridge.

Referring to FIGS. 50 and 51, the forming pocket arrangement 6500further comprises a bridge portion 6505 defined between the forming cups6510, 6530. In this instance, the bridge portion 6505 is recessed withrespect to the planar surface 6507 of the anvil 6501. The bridge portion6505 comprises a bridge width BW and a bridge depth BD (FIG. 54). Thebridge depth BD is the distance that the bottom portion of the bridgeportion 6505 is recessed with respect to the planar surface 6507. Thebridge width BW is the width of the pocket arrangement 6500 between thecups 6510, 6530. In this instance, the bridge width BW is the narrowestsection of the forming surfaces of each cup 6510, 6530. The formingpocket arrangement 6500 comprises a center C (FIGS. 48-50) definedwithin the bridge portion 6505. The forming pocket arrangement 6500 isbilaterally symmetric with respect to the bridge portion 6505,bilaterally symmetric with respect to pocket axis 6503, and rotationallysymmetric with respect to the center C.

The forming pocket arrangement 6500 further comprises a pair of primarysidewalls 6508 extending from the planar surface 6507 of the anvil 6501toward the cups 6510, 6530 and the bridge portion 6505. The primarysidewalls 6508 are angled at an angle θ₁ (FIGS. 52-54) with respect tothe planar surface 6507 of the anvil 6501. The cups 6510, 6530 define aperimeter 6520 and the inner edges of the primary sidewalls 6508 extendbetween the planar surface 6507 and the perimeter 6520 of the cups 6510,6530. Referring primarily to FIG. 50, the inner edges of the primarysidewalls 6508 are curved, or contoured, with respect to the cups 6510,6530.

In certain instances, the forming pocket arrangement 6500 may notinclude the primary sidewalls 6508. In such instances, the cups 6510,6530 can extend directly to the planar surface 6507 and the perimeter6520 of the cups 6510, 6530 can be defined in the planar surface 6507.

Referring again to FIGS. 50 and 51, the proximal forming cup 6510comprises a pair of cup sidewalls 6513 and the distal forming cup 6530comprises a pair of cup sidewalls 6533. The cup sidewalls 6513, 6533comprise curved, or contoured, profiles and are configured to direct thestaple tips and the legs of the staples toward the forming surfaces ofthe cups 6510, 6530 as well as help control the forming process of thestaples. The sidewalls 6513, 6533 extend from the primary sidewalls 6508and the planar surface 6507 toward the forming surfaces of each cup6510, 6530. The sidewalls 6513, 6533 are configured to encourage thestaple tips and/or the legs of the staples to form along the pocket axis6503 as the staples are formed against the forming surfaces of the cups6510, 6530. Collectively, the primary sidewalls 6508 and the cupsidewalls 6513, 6533 cooperate to funnel corresponding staple tipstoward the lateral center of each cup 6510, 6530. An inflection surface,or bottom surface, 6514, 6534 extends along the lateral center of eachrespective cup 6510, 6530 intermediate the respective sidewalls 6513,6533.

Referring still to FIG. 50, the forming surfaces of the cups 6510, 6530comprise an entry zone forming surface 6511, 6531, respectively, and anexit zone forming surface 6512, 6532, respectively. The entry zoneforming surfaces 6511, 6531 can coincide with less aggressive channelingportions of the sidewalls 6513, 6533. Similarly, the exit zone formingsurfaces 6512, 6532 can coincide with more aggressive channelingportions of the sidewalls 6513, 6533.

Referring primarily now to FIG. 51, the forming surfaces of each cup6510, 6530 are defined by a depth profile or contour. The proximalforming cup 6510 includes the depth profile 6522, and the distal formingcup 6530 includes the depth profile 6542. The depth profiles 6522, 6542define the depth of the cups 6510, 6530, respectively, along the lengththereof. The cups 6510, 6530 reach a maximum cup depth CD within theirrespective transition zones 6509, 6529, which are further describedbelow. The cup depth CD of the pockets 6510, 6530 can be between 0.3 and0.5 millimeters, for example. For example, the cup depth CD can be 0.4millimeters. In other instances, the cup depth CD can be less than 0.3millimeters or more than 0.5 millimeters, for example.

The depth profiles 6522, 6542 are curved profiles, which are devoid oflinear portions. Moreover, the depth profiles 6522, 6542 can compriseone or more radii of curvature. Specifically, the depth profile 6522 ofthe proximal forming cup 6510 comprises an entry radius of curvature6517 corresponding to the entry zone forming surface 6511 and an exitradius of curvature 6518 corresponding to the exit zone forming surface6512. Similarly, the depth profile 6542 of the distal forming cup 6530comprises an entry radius of curvature 6537 corresponding to the entryzone forming surface 6531 and an exit radius of curvature 6538corresponding to the exit zone forming surface 6532. In this instance,the entry radii of curvature 6517, 6537 are larger than the exit radiiof curvature 6518, 6538. Specific relationships between the entry zoneand exit zone radii of curvature and various pocket features along withsome potential advantages and patterns of the specific relationships arefurther described in U.S. patent application Ser. No. 15/385,914.

The outer longitudinal edges of each cup 6510, 6530 are referred to asentry edges because they define the beginning of the entry zone formingsurfaces 6511, 6531. The entry edges comprise an entry width which isthe largest width of the forming surfaces of each cup 6510, 6530. Theinner edges of each cup 6510, 6530 are referred to as exit edges becausethey define the end of the exit zone forming surfaces 6512, 6532. Theexit edges comprise an exit width, also referred to as the bridge widthBW (FIG. 54) which is the narrowest section of the forming surfaces ofeach cup 6510, 6530. A transition zone 6509, 6529 is positionedintermediate the entry zone and exit zone of each cup. The transitionzones 6509, 6529 have a transition width which is less than the entrywidth but greater than the exit width. The transition zones 6509, 6529include an inflection portion of the respective depth profiles 6522,6542 and, thus, include the deepest portion of each cup 6510, 6530. Invarious instances, the transition zones 6509, 6529 comprise the majorityof the length of each cup 6510, 6530. More specifically, the length ofthe transition zone 6509, 6529 can be greater than the combined lengthof the respective entry zone and exit zone of each cup 6510, 6530. Thetransition zones 6509, 6529 can extend along the tapered or narrowingsection of each cup 6510, 6530. For example, each transition zone 6509,6529 can extend inward from the widest section of the respective cup6510, 6530 toward the bridge 6505.

FIG. 53 is a cross-sectional view of the distal forming cup 6530 takenalong line 53-53 in FIG. 50. This view is taken near the valley, ortrough, of the distal forming cup 6530. This valley, or trough, is alsothe transition between the entry zone forming surface 6531 and the exitzone forming surface 6532. In various instances, the transition betweenentry and exit zones does not occur at the valley, or trough, of thecup. FIG. 54 illustrates a cross-sectional view of the distal formingcup 6530 taken along line 54-54 in FIG. 50 which is located within theexit zone forming surface 6532 of the distal forming cup 6530. FIG. 52is a cross-sectional view of the distal forming cup 6530 taken alongline 52-52 in FIG. 50 which is within the entry zone forming surface6532 of the distal forming cup 6530.

Referring primarily to FIGS. 52-54, the pair of cup sidewalls 6533 ofthe distal forming cup 6530 includes a first sidewall 6533 a and asecond sidewall 6533 b. The first and second sidewalls 6533 a, 6533 bare opposing sidewalls which extend toward each other fromlaterally-opposed sides of the distal forming cup 6530. The inflectionsurface, or bottom surface, 6534 of the distal forming cup 6530 ispositioned between the first and second sidewalls 6533 a, 6533 b. Thebottom surface 6534 of the distal forming cup 6530 is anentirely-curved, non-flat surface. In other words, the bottom surface6534 is devoid of flat, planar surfaces. The bottom surface 6534 candefine one or more radii of curvature. For example, at variouslongitudinal positions along the pocket axis 6503, the bottom surface6534 defines different radii of curvature. A tangent to the bottomsurface 6534 at the lateral center of the cup 6530 is parallel to theplanar surface 6507 along the length thereof.

In various instances, the curvature of the bottom surface 6534 can bedimensioned such that the staple leg does not travel along a flatsurface during the staple forming process. In such instances, the bottomsurface 6543 can encourage the staple to form into a more planar formedconfiguration than staples formed along flat bottom surfaces, especiallywhen the staples are misaligned with the pocket axis 6503 duringformation. The curvature of the bottom surface 6543 can be dimensionedsuch that the bottom surface 6543 provides a plurality of contactsurfaces for the staple leg. For example, the radius of curvature of thebottom surface 6534 can be less than the radius of curvature of thestaple leg.

The cup sidewalls 6513, 6533 are entirely-curved, non-flat surfaces. Inother words, the cup sidewalls 6513, 6533 are devoid of flat, planarsurfaces. Referring again to FIGS. 52-54, the sidewalls 6533 a, 6533 bdefine one or more radii of curvature. For example, at variouslongitudinal positions along the pocket axis 6503, the sidewalls 6533 a,6533 b define different radii of curvature. The entirely-curved contoursof the cup sidewalls 6513, 6533 and the bottom surface 6534 can definecurvilinear boundary surfaces of the cups 6510, 6530. The cups 6513,6533 can be entirely-curved and devoid of flat, planar surfaces.

The sidewalls 6533 a, 6533 b are oriented at an entry angle θ₂ relativeto the tissue-contacting surface 6507 at various transversecross-sections of the distal forming cup 6530. More specifically, atangent T to each sidewall 6533 a, 6533 b at the perimeter 6520 of thedistal forming cup 6530 is oriented at the angle θ₂ relative to thetissue-contacting surface 6507 in FIGS. 52-54. The entry angle θ₂ isconstant within the transition forming zone 6529 (FIGS. 50 and 51) andalong the majority of the length of the distal forming cup 6530. Thoughthe tangent to such sidewalls is oriented at a constant angle along thelength, or substantial length, of the cups 6510, 6530, the radius ofcurvature and the length of the arcs defining the sidewalls can vary asthe depth and width of the cups varies along the length thereof. Invarious instances, the angle θ₂ can be between 55 degrees and 80degrees, for example. For example, in FIGS. 52-54, the angle θ₂ is 80degrees. In other instances, the angle θ₂ can be less than 55 degrees ormore than 80 degrees. The sidewalls 6533 a, 6533 b are non-verticalsidewalls and, thus, the angle θ₂ of the tangent T along the perimeter6520 can be less than 90 degrees, for example.

A datum point at the transition between the sidewalls 6533 a, 6533 b andthe bottom surface 6534 is indicated for illustrative purposes in FIGS.52-54. For example, the curved boundary surface of the distal formingcup 6530 includes a datum point A at the transition between the sidewall6533 a and the bottom surface 6534. At each longitudinal position alongthe cup 6530, the first sidewall 6533 a and the second sidewall 6533 bdefine a sidewall radius of curvature 6543 and the bottom surface 6534defines a bottom radius of curvature 6544. The bottom radius ofcurvature 6544 can be different than the sidewall radius of curvature6543. The transition between radii of curvature at the datum point Acomprises a smooth, non-abrupt transition.

A datum line B is also depicted in FIGS. 52-54 for illustrativepurposes. The datum line B extends between the first datum point A andthe perimeter 6520 of the distal forming cup 6530. The datum line B isoriented at an angle θ₃ in FIGS. 52-54. The angle θ₃ can determine wherethe curved sidewall 6533 a meets the curved bottom surface 6534.Moreover, the steepness of the sidewall 6533 a can be impacted by theangle θ₃. For example, for a constant angle θ₂, an increase in the angleθ₃ can result in a deeper and narrower cup. In certain instances, theangle θ₃ can be limited by a desirable minimum pocket width in thedeepest portion of the cup. For example, the desirable minimum pocketwidth can be a requirement of the tooling process for the anvil 6501and/or necessitated by the width of the staple wire.

The angle θ₃ is constant within the transition forming surface zone 6529(FIG. 51) and along the majority of the length of the distal forming cup6530. In various instances, the angle θ₃ can be less than the angle θ₂.The angle θ₃ in FIGS. 52-54 is approximately 55 degrees, for example. Inother instances, the angle θ₃ can be less than 55 degrees or more than80 degrees, for example. Though the angles θ₂ and θ₃ are constant alongthe length of the distal forming cup 6530, or at least along thesubstantial length of the distal forming cup 6530, the radius ofcurvature and the length of the arcs defining the sidewalls 6533 a, 6533b varies as the depth and width of the distal forming cup 6530 variesalong the length thereof.

The angle θ₂ relative to a tissue-contacting surface can comprise arelatively steep angle. For example, the angle θ₂ can be greater thanthe angles θ₁ and θ₃. The steepness of the angle θ₂ can encourage thestaple to form along the pocket axis. Moreover, a constant angle θ₂along the length of the distal forming cup 6530 can encourage amisaligned staple leg to move from the perimeter toward the lateralcenter or axis 6503 of the cup 6530. As described herein, the depth ofthe pocket can vary along the length thereof. However, maintaining aconstant angle θ₂ can encourage a misaligned staple leg to move from theperimeter toward the lateral center of the distal forming cup 6530 evenin shallower regions of the cup 6530.

In certain instances, the maximum cup depth CD can vary betweenstaple-forming pockets and/or arrangements in an anvil. For example,different depths can be utilized to form staples to different heightsand/or to form staples driven by drivers having different heights, asfurther described herein. The depth of the pockets can vary across therows of pockets and/or within one or more rows of pockets, for example.Deeper pockets can provide increased control over staple formation;however, the depth of the pockets can be limited by anvil toolingconstraints and the geometry of the staples. In instances in whichcertain pockets are shallower than other pockets, the sidewalls of theshallower pockets can be oriented at the same entry angle θ₂ as thedeeper pockets to encourage the staples formed by the shallower pocketsto form along the pocket axis.

FIG. 54A is a partial negative view of various slices of a formingpocket of the forming pocket arrangement 6500. The dimensions of thevarious slices are labeled thereon. The slices are of only a singlesidewall of the forming pocket and are taken in planes along the formingpocket which are perpendicular to the tissue-contacting surface 6507 andthe pocket axis 6503. Each slice comprises a width “x”, a height “y”, anupper radius of curvature “ra”, and a lower radius of curvature “rb”.The width “x” is defined as the x-component of the distance between theperimeter 6520 of the forming pocket and the bottom radius of curvature6544 of the forming pocket. The height “y” is defined as the y-componentof the distance between the perimeter 6520 of the forming pocket and thebottom radius of curvature 6544 of the forming pocket. The upper radiusof curvature “ra” is defined as the radius of curvature of an upperportion of the sidewall. The lower radius of curvature “rb” is definedas the radius of curvature of an lower portion of the sidewall. Eachdimension includes a number indicating which slice the dimensioncorresponds to. For example, Slice 1 includes a width “x₁”, a height“y₁”, an upper radius of curvature “ra₁”, and a lower radius ofcurvature “rb₁”. FIG. 54B is a table 6550 comprising the dimensions ofthe Slices 1-12 of FIG. 54A, in at least one embodiment.

FIG. 54C is a cross-sectional view of the forming pocket arrangement6500 taken along the pocket axis 6503. FIG. 54C includes variousdimensions of the distal forming pocket 6530 of forming pocketarrangement 6500. The length of the forming pocket 6530 is 1.90 mm, forexample. The depth of the forming pocket 6530 is 0.40 mm, for example.In certain instances, the distal forming pocket 6530 comprises threeradii of curvature: an entry radius of curvature which is 1.90 mm, afirst exit radius of curvature which is 1.00 mm, and a second exitradius of curvature which is 0.10 mm, for example. The width of thebridge portion of the distal forming pocket 6530 is defined, in thisinstance, as the distance between the center of the forming pocketarrangement 6500 and the inner-most edge of the first exit radius ofcurvature (the edge of the first exit radius of curvature closest to thecenter of the forming pocket arrangement 6500) is 0.10 mm, for example.The bridge depth is 0.05 mm, for example.

FIGS. 55-60 depict another forming pocket arrangement 6600 in the anvil6501. The forming pocket arrangement 6600 is configured to deform astaple during a surgical stapling procedure, and comprises a proximalforming cup, or pocket, 6610 and a distal forming cup, or pocket, 6630defined in the planar, or tissue-contacting, surface 6507 of the anvil6501. The forming pocket arrangement 6600 can be similar in manyrespects to the forming pocket arrangement 6500. For example, sidewallsof the staple-forming cups 6610, 6630 can intersect the planar surface6507 at the same constant entry angle θ₂ along the length thereof.Though the sidewall entry angles θ₂ can be the same for cups 6610 and6630 as for cups 6510 and 6530 (FIGS. 48-54), the maximum cup depth CDcan be different, as further described herein. In such instances, thesidewalls of the shallower pockets can define the same entry angle θ₂ asthe sidewalls of the deeper pockets, which can encourage proper, planarformation of the staples formed by the different depth pockets.

In other instances, the forming pocket arrangement 6600 can be definedin a different anvil. For example, the anvil 6501 may not includedifferent forming pocket arrangements. Rather, an anvil, such as theanvil 6501, can consist of uniform or identical forming pocketarrangements, for example. In certain instances, the forming pocketarrangement 6600 can be the only forming pocket arrangement in aparticular anvil.

Each cup 6610, 6630 is defined by a boundary surface as furtherdescribed herein. The cups 6610, 6630 are aligned along a pocket axis6603 of the forming pocket arrangement 6600. A staple is intended to beformed along the pocket axis 6603 by the forming pocket arrangement 6600when deployed from a staple cartridge. For example, a first leg of thestaple can be formed by the proximal forming cup 6610 and a second legof the staple can be formed by the distal forming cup 6630. In suchinstances, the first leg of the staple is aligned with a portion of theproximal forming cup 6610 and the second leg of the staple is alignedwith a portion of the distal forming cup 6630 when the anvil 6501 isclamped relative to the staple cartridge.

Referring to FIGS. 56 and 57, the forming pocket arrangement 6600further comprises a bridge portion 6605 defined between the forming cups6610, 6630. The bridge portion 6605 is recessed with respect to theplanar surface 6507 of the anvil 6501, however, the bridge portion 6605can be flush with the planar surface 6507. The bridge portion 6605comprises a bridge width BW and a bridge depth BD (FIG. 60). The bridgedepth BD is the distance that the bottom portion of the bridge portion6605 is recessed with respect to the planar surface 6507. The bridgewidth BW is the width of the pocket arrangement 6600 between the cups6610, 6630. In this instance, the bridge width BW is the narrowestsection of the forming surfaces of each cup 6610, 6630. The formingpocket arrangement 6600 comprises a center C (FIGS. 55 and 56) definedwithin the bridge portion 6605. The forming pocket arrangement 6600 isbilaterally symmetric with respect to the bridge portion 6605,bilaterally symmetric with respect to pocket axis 6603, and rotationallysymmetric with respect to the center C.

The forming pocket arrangement 6605 further comprises a pair of primarysidewalls 6608 extending from the planar surface 6507 of the anvil 6501toward the cups 6610, 6630 and the bridge portion 6605. The primarysidewalls 6608 are angled at an angle θ₁ (FIGS. 58-60) with respect tothe planar surface 6507 of the anvil 6501. The cups 6610, 6630 define aperimeter 6620 and the inner edges of the primary sidewalls 6608 extendbetween the planar surface 6507 and the perimeter 6620 of the cups 6610,6630. Referring primarily to FIG. 56, the inner edges of the primarysidewalls 6608 are curved, or contoured, with respect to the cups 6610,6630.

In certain instances, the forming pocket arrangement 6600 may notinclude the primary sidewalls 6608. In such instances, the cups 6610,6630 can extend directly to the planar surface 6507 and the perimeter6620 of the cups 6610, 6630 can be defined in the planar surface 6507.

Referring again to FIGS. 56 and 57, the proximal forming cup 6610comprises a pair of cup sidewalls 6613 and the distal forming cup 6630comprises a pair of cup sidewalls 6633. The cup sidewalls 6613, 6633comprise curved, or contoured, profiles and are configured to direct thestaple tips and the legs of the staples toward the forming surfaces ofthe cups 6610, 6630 as well as help control the forming process of thestaples. The sidewalls 6613, 6633 extend from the primary sidewalls 6608and the planar surface 6507 toward the forming surfaces of each cup6610, 6630. The sidewalls 6613, 6633 are configured to encourage thestaple tips and/or the legs of the staples to form along the pocket axis6603 as the staples are formed against the forming surfaces of the cups6610, 6630. Collectively, the primary sidewalls 6608 and the cupsidewalls 6613, 6633 cooperate to funnel corresponding staple tipstoward the lateral center of each cup 6610, 6630. An inflection surface,or bottom surface, 6614, 6634 extends along the lateral center of eachrespective cup 6610, 6630 intermediate the respective sidewalls 6613,6633.

Referring still to FIG. 56, the forming surfaces of the cups 6610, 6630comprise an entry zone forming surface 6611, 6631, respectively, and anexit zone forming surface 6612, 6632, respectively. The entry zoneforming surfaces 6611, 6631 can coincide with less aggressive channelingportions of the sidewalls 6613, 6633. Similarly, the exit zone formingsurfaces 6612, 6632 can coincide with more aggressive channelingportions of the sidewalls 6613, 6633.

Referring primarily now to FIG. 57, the forming surfaces of each cup6610, 6630 are defined by a depth profile or contour. The proximalforming cup 6610 includes the depth profile 6622, and the distal formingcup 6630 includes the depth profile 6642. The depth profiles 6622, 6642define the depth of the cups 6610, 6630, respectively, along the lengththereof. The cups 6610, 6630 reach a maximum cup depth CD within theirrespective transition zone 6609, 6629, which are further describedbelow. The cup depth CD of the pockets 6610, 6630 can be between 0.2 and0.4 millimeters, for example. For instance, the cup depth CD can be 0.3millimeters. In other instances, the cup depth CD can be less than 0.2millimeters or more than 0.4 millimeters.

The cup depth CD of the cups 6610, 6630 is less than the cup depth CD ofthe cups 6510, 6530 (FIG. 51). For example, the cup depth CD of the cups6610, 6630 can be 0.2 millimeters less than the cup depth CD of the cups6510, 6530. In certain instances, the cup depth CD of the cups 6610,6630 can be 0.1 millimeters to 0.3 millimeters less than the cup depthCD of the cups 6510, 6530. The cup depth CD of the cups 6510, 6530 canbe 25% to 50% greater than the cup depth CD of the cups 6610, 6630. Forexample, the cup depth CD of the cups 6510, 6530 can be 40% greater thanthe cup depth CD of the cups 6610, 6630. In various instances, thedifference between the cup depth CD of the pocket forming arrangements6500 and 6600 can be selected to be equal to, or substantially equal to,the diameter of a staple formed by the pocket forming arrangements 6500,6600.

The depth profiles 6622, 6642 are curved profiles, which are devoid oflinear portions. Moreover, the depth profiles 6622, 6642 can compriseone or more radii of curvature. In this instance, the depth profiles6622, 6642 include more than one radius of curvature. Specifically, thedepth profile 6622 of the proximal forming cup 6610 comprises an entryradius of curvature 6617 corresponding to the entry zone forming surface6611 and an exit radius of curvature 6618 corresponding to the exit zoneforming surface 6612. Similarly, the depth profile 6642 of the distalforming cup 6630 comprises an entry radius of curvature 6637corresponding to the entry zone forming surface 6631 and an exit radiusof curvature 6638 corresponding to the exit zone forming surface 6632.In this instance, the entry radii of curvature 6617, 6637 are largerthan the exit radii of curvature 6618, 6638. Specific relationshipsbetween the entry and exit radii of curvature and various pocketfeatures along with some potential advantages and patterns of thespecific relationships are further described in U.S. patent applicationSer. No. 15/385,914.

The outer longitudinal edges of each cup 6610, 6630 are referred to asentry edges because they define the beginning of the entry zone formingsurfaces 6611, 6631. The entry edges comprise an entry width which isthe largest width of the forming surfaces of each cup 6610, 6630. Theinner edges of each cup 6610, 6630 are referred to as exit edges becausethey define the end of the exit zone forming surfaces 6612, 6632. Theexit edges comprise an exit width, also referred to as the bridge widthBW (FIG. 60) which is the narrowest section of the forming surfaces ofeach cup 6610, 6630. A transition zone 6609, 6629 is positionedintermediate the entry zone and exit zone of each cup. The transitionzones 6609, 6629 have a transition width which is less than the entrywidth but greater than the exit width. The transition zones 6609, 6629include an inflection portion of the respective depth profiles 6622,6642 and, thus, include the deepest portion of each cup 6610, 6630. Invarious instances, the transition zones 6609, 6629 comprise the majorityof the length of each cup 6610, 6630. More specifically, the length ofthe transition zone 6609, 6629 can be greater than the combined lengthof the respective entry zone and exit zone of each cup 6610, 6630. Thetransition zones 6609, 6629 can extend along the tapered or narrowingsection of each cup 6610, 6630. For example, each transition zone 6609,6629 can extend inward from the widest section of the respective cup6610, 6630 toward the bridge 6605.

FIG. 59 is a cross-sectional view of the distal forming cup 6630 takenalong line 59-59 in FIG. 56. This view is taken near the valley, ortrough, of the distal forming cup 6630. This valley, or trough, is alsothe transition between the entry zone forming surface 6631 and the exitzone forming surface 6632. In various instances, the transition betweenentry and exit zones does not occur at the valley, or trough, of thecup. FIG. 60 illustrates a cross-sectional view of the distal formingcup 6630 taken along line 60-60 in FIG. 56 which is located within theexit zone forming surface 6632 of the forming cup 6630. FIG. 58 is across-sectional view of the distal forming cup 6630 taken along line58-58 in FIG. 56 which is located within the entry zone forming surface6632 of the distal forming cup 6630.

Referring primarily to FIGS. 58-60, the pair of cup sidewalls 6633 ofthe distal forming cup 6630 includes a first sidewall 6633 a and asecond sidewall 6633 b. The first and second sidewalls 6633 a, 6633 bare opposing sidewalls which extend toward each other fromlaterally-opposed sides of the distal forming cup 6630. The inflectionsurface, or bottom surface, 6634 of the distal forming cup 6630 ispositioned between the first and second sidewalls 6633 a, 6633 b. Thebottom surface 6634 of the distal forming cup 6630 is anentirely-curved, non-flat surface. In other words, the bottom surface6634 is devoid of flat, planar surfaces. The bottom surface 6634 candefine one or more radii of curvature. For example, at variouslongitudinal positions along the pocket axis 6603, the bottom surface6634 defines different radii of curvature. A tangent to the bottomsurface 6634 at the lateral center of the cup 6630 is parallel to theplanar surface 6507 along the length thereof.

In various instances, the curvature of the bottom surface 6634 can bedimensioned such that the staple leg does not travel along a flatsurface during the staple forming process. In such instances, the bottomsurface 6643 can encourage staples to form into a more planar formedconfiguration than staples formed along flat bottom surfaces, especiallywhen the staples are misaligned with the pocket axis 6603 duringformation. The curvature of the bottom surface 6643 can be dimensionedsuch that the bottom surface 6643 provides a plurality of contactsurfaces for the staple leg. For example, the radius of curvature of thebottom surface 6634 can be less than the radius of curvature of thestaple leg.

The cup sidewalls 6613, 6633 are entirely-curved, non-flat surfaces. Inother words, the cup sidewalls 6613, 6633 are devoid of flat, planarsurfaces. Referring again to FIGS. 58-60, the sidewalls 6633 a, 6633 bdefine one or more radii of curvature. For example, at variouslongitudinal positions along the pocket axis 6603, the sidewalls 6633 a,6633 b define different radii of curvature. The entirely-curved contoursof the cup sidewalls 6613, 6633 and the bottom surface 6634 can definecurvilinear boundary surfaces of the cups 6610, 6630. The cups 6613,6633 can be entirely-curved and devoid of flat, planar surfaces.

The sidewalls 6633 a, 6633 b are oriented at an entry angle θ₂ relativeto the tissue-contacting surface 6507 at various transversecross-sections of the distal forming cup 6630. More specifically, atangent T to each sidewall 6633 a, 6633 b at the perimeter 6620 of thedistal forming cup 6630 is oriented at the angle θ₂ relative to thetissue-contacting surface 6507 in FIGS. 58-60. The entry angle θ₂ isconstant within the transition forming surface zone 6629 (FIGS. 56 and57) and along the majority of the length of the distal forming cup 6630.In various instances, the angle θ₂ can be between 55 degrees and 80degrees, for example. For instance, in FIGS. 58-60, the angle θ₂ is 80degrees. In other instances, the angle θ₂ can be less than 55 degrees ormore than 80 degrees. The sidewalls 6633 a, 6633 b are non-verticalsidewalls and, thus, the angle θ₂ of the tangent T along the perimeter6620 can be less than 90 degrees, for example.

A datum point at the transition between the sidewalls 6633 a, 6633 b andthe bottom surface 6634 is indicated for illustrative purposes in FIGS.58-60. For example, the curved boundary surface of the distal formingcup 6630 includes a datum point A at the transition between the sidewall6633 a and the bottom surface 6634. At each longitudinal position alongthe cup 6630, the first sidewall 6633 a and the second sidewall 6633 bdefine a sidewall radius of curvature 6643 and the bottom surface 6634defines a bottom radius of curvature 6644. The bottom radius ofcurvature 6644 can be different than the sidewall radius of curvature6643. The transition between radii of curvature at the datum point Acomprises a smooth, non-abrupt transition.

A datum line B is also depicted in FIGS. 58-60 for illustrativepurposes. The datum line B extends between the first datum point A andthe perimeter 6620 of the distal forming cup 6630. The datum line B isoriented at an angle θ₃ in FIGS. 58-60. The angle θ₃ is constant withinthe transition forming surface zone 6629 (FIG. 57) and along themajority of the length of the distal forming cup 6630. In variousinstances, the angle θ₃ can be less than the angle θ₂. The angle θ₃ inFIGS. 58-60 is approximately 55 degrees, for example. In otherinstances, the angle θ₃ can be less than 55 degrees or more than 80degrees. Though the angles θ₂ and θ₃ are constant along the length ofthe distal forming cup 6630, or at least along the substantial length ofthe distal forming cup 6630, the radius of curvature and the length ofthe arcs defining the sidewalls 6633 a, 6633 b varies as the depth andwidth of the distal forming cup 6630 varies along the length thereof.

The angle θ₂ relative to a tissue-contacting surface can comprise arelatively steep angle. For example, the angle θ₂ can be greater thanthe angles θ₁ and θ₃. The steepness of the angle θ₂ can encourage thestaple to form along the pocket axis. A constant angle θ₂ can encouragea misaligned staple leg to move from the perimeter toward the lateralcenter or axis 6603 of the distal forming cup 6630. As described herein,the depth of the pocket can vary along the length thereof. However,maintaining a constant angle θ₂ can encourage a misaligned staple leg tomove from the perimeter toward the lateral center of the distal formingcup 6630 even in shallower regions of the cup 6630.

Pocket arrangements having different cup depths CD can be dimensioned tohave the same angles θ₂ and θ₃. For example, though the cup depth CD ofthe cups 6610, 6630 (FIG. 57) is less than the cup depth CD of the cups6510, 6530 (FIG. 51), the angles θ₂ and θ₃ can be the same. In at leastone instance, the angle θ₂ can be 80 degrees and the angle θ₃ can be 55degrees for both forming pocket arrangements 6500 and 6600. In instancesin which the tissue-contacting surface 6507 comprises a planar surface,the pocket forming arrangement 6600 can be configured to form staples toa reduced height in comparison to the pocket forming arrangement 6500.For example, a staple formed by the pocket forming arrangement 6600 canbe shorter than an identical staple formed by the pocket formingarrangement 6500. In certain instances, variations to the formed heightof the staples can be desirable to control the tissue compression and/orfluid flow between the anvil and the staple cartridge, for example.Though variations to the cup depth CD can be configured to control theformed height of the staples, maintaining constant entrance angles θ₂along the length, or at least a substantial portion of the length, ofthe different cups can be configured to ensure that even the shorterformed staples are formed to a more consistent, planar configuration,which is desirable in certain instances.

FIGS. 68 and 69 depict a staple 6701 formed with the forming pocketarrangement 6600 (FIGS. 55-60) where the staple 6701 was aligned withthe pocket axis 6603 of the forming pocket arrangement 6600 during theforming process. FIG. 68 depicts a top view of the staple 6701 in afully-formed configuration and FIG. 69 depicts a side view of the staple6701 in the fully-formed configuration. The staple includes a base 6702and staple legs 6703 that extend from the base 6702. The base 6702 isaligned with the pocket axis 6603 and the tips 6704 of the staple legs6703 strike the forming pocket arrangement 6600 along the pocket axis6603.

The staple 6701 comprises a centerline CL (FIG. 69) which transects thebase 6702 and extends vertically intermediate the unformed staple legs6703. As the staple 6701 is formed to the fully-formed configuration,the tips 6704 of the staple legs 6703 are bent toward the centerline CLand toward the base 6702. The staple legs 6703 are formed such that thestaple 6701 defines a height H (FIG. 69) when in the fully-formedconfiguration. The height H can be less than the height of the staple6701 if it had been formed with the forming pocket arrangement 6500(FIGS. 48-54) because the cup depth CD of the cups 6610, 6630 (FIG. 57)is less than the cup depth CD of the cups 6510, 6530 (FIG. 51).

To achieve the shorter height H, a portion of the staples legs 6703 candeflect laterally relative to the centerline CL and/or the tips 6704 ofthe staple legs 6702 can extend up to and/or below the base 6704.Comparatively, if the staple 6701 had been formed with the formingpocket arrangement 6500 having the deeper cup depth CD, the staple legs6703 may not deflect laterally relative to the centerline CL and/or thetips 6704 of the staple legs 6702 may not overlap the base 6704 (see,e.g., staple 13100 (FIG. 46)). Referring to FIG. 69, a portion of eachstaple leg 6703 crosses the centerline CL and the tips 6704 of thestaple legs 6702 extend past, or below, a tissue-compressing surface ofthe base 6702. Moreover, the staple 6701 comprises a first tip alignmentaxis TA1, a second tip alignment axis TA2, and a crown alignment axisCA. When aligned with the pocket axis 6603, the staple 6701 forms suchthat the first tip alignment axis TA1 and the second tip alignment axisTA2 are laterally offset and equidistant (D) from the crown alignmentaxis CA. The distance D can be approximately equal to the diameter ofthe staple 6701. As a result of the above, the staple 6701 assumes asubstantially planar configuration; however, the tips 6704 are slightlyoverlapping and offset from the base 6702 to achieve the shorter heightH.

FIG. 60A is a partial negative view of various slices of a formingpocket of the forming pocket arrangement 6600. The dimensions of thevarious slices are labeled thereon. The slices are of only a singlesidewall of the forming pocket and are taken in planes along the formingpocket which are perpendicular to the tissue-contacting surface 6507 andthe pocket axis 6603. Each slice comprises a width “x”, a height “y”, anupper radius of curvature “ra”, and a lower radius of curvature “rb”.The width “x” is defined as the x-component of the distance between theperimeter 6620 of the forming pocket and the bottom radius of curvature6644 of the forming pocket. The height “y” is defined as the y-componentof the distance between the perimeter 6620 of the forming pocket and thebottom radius of curvature 6644 of the forming pocket. The upper radiusof curvature “ra” is defined as the radius of curvature of an upperportion of the sidewall. The lower radius of curvature “rb” is definedas the radius of curvature of an lower portion of the sidewall. Eachdimension includes a number indicating which slice the dimensioncorresponds to. For example, Slice 1 includes a width “x₁”, a height“y₁”, an upper radius of curvature “ra₁”, and a lower radius ofcurvature “rb₁”. FIG. 60B is a table 6650 comprising the dimensions ofthe Slices 1-12 of FIG. 60A, in at least one embodiment.

FIG. 60C is a cross-sectional view of the forming pocket arrangement6600 taken along the pocket axis 6603. FIG. 60C includes variousdimensions of the distal forming pocket 6630 of forming pocketarrangement 6600. The length of the forming pocket 6630 is 1.90 mm, forexample. The depth of the forming pocket 6630 is 0.30 mm, for example.In certain instances, the distal forming pocket 6630 comprises threeradii of curvature: an entry radius of curvature which is 2.90 mm, afirst exit radius of curvature which is 0.70 mm, and a second exitradius of curvature which is 0.10 mm, for example. The width of thebridge portion of the distal forming pocket 6630 is defined, in thisinstance, as the distance between the center of the forming pocketarrangement 6600 and the inner-most edge of the first exit radius ofcurvature (the edge of the first exit radius of curvature closest to thecenter of the forming pocket arrangement 6600) is 0.10 mm, for example.The bridge depth is 0.05 mm, for example.

FIGS. 61-67 depict a forming pocket arrangement 6800 that is configuredto deform a staple during a surgical stapling procedure. The formingpocket arrangement 6800 comprises a proximal forming cup, or pocket,6810 and a distal forming cup, or pocket, 6830 defined in a planar, ortissue-contacting, surface 6807 of an anvil 6801. The tissue-contactingsurface 6807 of the anvil 6801 is configured to compress tissue againsta staple cartridge when the anvil 6801 is clamped or closed relative tothe staple cartridge. The forming pocket arrangement 6800 can be similarin many respects to the forming pocket arrangement 6500. For example,sidewalls of the staple-forming cups 6810, 6830 intersect the planarsurface 6807 at a constant angle along the length thereof. Each cup6810, 6830 is defined by a boundary surface as further described herein.The cups 6810, 6830 are aligned along a pocket axis 6803 of the formingpocket arrangement 6800. A staple is intended to be formed along thepocket axis 6803 by the forming pocket arrangement 6800 when deployedfrom a staple cartridge. In at least one such instance, a first leg ofthe staple can be formed by the proximal forming cup 6810 and a secondleg of the staple can be formed by the distal forming cup 6830. In suchinstances, the first leg of the staple is aligned with a portion of theproximal forming cup 6810 and the second leg of the staple is alignedwith a portion of the distal forming cup 6830 when the anvil 6801 isclamped relative to the staple cartridge.

Referring to FIGS. 62 and 63, the forming pocket arrangement 6800further comprises a bridge portion 6805 defined between the forming cups6810, 6830. The bridge portion 6805 is recessed with respect to theplanar surface 6807 of the anvil 6801; however, the bridge portion 6805can be flush with the planar surface 6807 in other embodiments. Thebridge portion 6805 comprises a bridge width BW and a bridge depth BD(FIG. 67). The bridge depth BD is the distance that the bottom portionof the bridge portion 6805 is recessed with respect to the planarsurface 6807. The bridge width BW is the width of the pocket arrangement6800 between the cups 6810, 6830. In this instance, the bridge width BWis the narrowest section of the forming surfaces of each cup 6810, 6830.The forming pocket arrangement 6800 comprises a center C (FIGS. 61 and62) defined within the bridge portion 6805. The forming pocketarrangement 6800 is bilaterally symmetric with respect to the bridgeportion 6805, bilaterally symmetric with respect to pocket axis 6803,and rotationally symmetric with respect to the center C.

The forming pocket arrangement 6800 further comprises a pair of primarysidewalls 6808 extending from the planar surface 6807 of the anvil 6801toward the cups 6810, 6830 and the bridge portion 6805. The primarysidewalls 6808 are angled at angle θ₁ (FIG. 64) with respect to theplanar surface 6807 of the anvil 6801. The cups 6810, 6830 define aperimeter 6820 and the inner edges of the primary sidewalls 6808 extendbetween the planar surface 6807 and the perimeter 6820 of the cups 6810,6830. Referring primarily to FIG. 62, the inner edges of the primarysidewalls 6808 are curved, or contoured, with respect to the cups 6810,6830. In certain instances, the forming pocket arrangement 6800 may notinclude the primary sidewalls 6808. In such instances, the cups 6810,6830 can extend directly to the planar surface 6807 and the perimeter6820 of the cups 6810, 6830 can be defined in the planar surface 6807.

Referring again to FIGS. 62 and 63, the proximal forming cup 6810comprises a pair of cup sidewalls 6813 and the distal forming cup 6830comprises a pair of cup sidewalls 6833. The cup sidewalls 6813, 6833comprise curved, or contoured, profiles and are configured to direct thestaple tips and the legs of the staples toward the forming surfaces ofthe cups 6810, 6830 as well as help control the forming process of thestaples. The sidewalls 6813, 6833 extend from the primary sidewalls 6808and the planar surface 6807 toward the forming surfaces of each cup6810, 6830. The sidewalls 6813, 6833 are configured to encourage thestaple tips and/or the legs of the staples to form along the pocket axis6803 as the staples are formed against the forming surfaces of the cups6810, 6830. Collectively, the primary sidewalls 6808 and the cupsidewalls 6813, 6833 cooperate to funnel corresponding staple tipstoward the lateral center of each cup 6810, 6830. An inflection surface,or bottom surface, 6814, 6834 extends along the lateral center of eachrespective cup 6810, 6830 intermediate the respective sidewalls 6813,6833.

Referring still to FIG. 62, the forming surfaces of the cups 6810, 6830comprise an entry zone forming surface 6811, 6831, respectively, and anexit zone forming surface 6812, 6832, respectively. The entry zoneforming surfaces 6811, 6831 can coincide with less aggressive channelingportions of the sidewalls 6813, 6833. Similarly, the exit zone formingsurfaces 6812, 6832 can coincide with more aggressive channelingportions of the sidewalls 6813, 6833.

Referring primarily now to FIG. 63, the forming surfaces of each cup6810, 6830 are defined by a depth profile or contour. The proximalforming cup 6810 includes the depth profile 6822, and the distal formingcup 6830 includes the depth profile 6842. The depth profiles 6822, 6842define the depth of the cups 6810, 6830, respectively, along the lengththereof. The cups 6810, 6830 reach a maximum cup depth CD within theirrespective transition zone 6809, 6829, which are further describedbelow. The cup depth CD of the pockets 6810, 6830 can be between 0.4 and0.6 millimeters, for example. For instance, the cup depth CD can be 0.5millimeters. In other instances, the cup depth CD can be less than 0.4millimeters or more than 0.6 millimeters.

The depth profiles 6822, 6842 are curved profiles which are devoid oflinear portions. Moreover, the depth profiles 6822, 6842 can compriseone or more radii of curvature. In this instance, the depth profiles6822, 6842 include more than one radius of curvature. Specifically, thedepth profile 6822 of the proximal forming cup 6810 comprises an entryradius of curvature 6817 corresponding to the entry zone forming surface6811 and an exit radius of curvature 6818 corresponding to the exit zoneforming surface 6812. Similarly, the depth profile 6842 of the distalforming cup 6830 comprises an entry radius of curvature 6837corresponding to the entry zone forming surface 6831 and an exit radiusof curvature 6838 corresponding to the exit zone forming surface 6832.In this instance, the entry radii of curvature 6817, 6837 are largerthan the exit radii of curvature 6818, 6838. Specific relationshipsbetween the entry and exit radii of curvature and various pocketfeatures along with some potential advantages and patterns of thespecific relationships are further described in U.S. patent applicationSer. No. 15/385,914.

The outer longitudinal edges of each cup 6810, 6830 are referred to asentry edges because they define the beginning of the entry zone formingsurfaces 6811, 6831. The entry edges comprise an entry width which isthe largest width of the forming surfaces of each cup 6810, 6830. Theinner edges of each cup 6810, 6830 are referred to as exit edges becausethey define the end of the exit zone forming surfaces 6812, 6832. Theexit edges comprise an exit width, also referred to as the bridge widthBW (FIG. 67) which is the narrowest section of the forming surfaces ofeach cup 6810, 6830. A transition zone 6809, 6829 is positionedintermediate the entry zone and exit zone of each cup. The transitionzones 6809, 6829 have a transition width which is less than the entrywidth but greater than the exit width. The transition zones 6809, 6829include an inflection portion of the respective depth profiles 6822,6842 and, thus, include the deepest portion of each cup 6810, 6830. Invarious instances, the transition zones 6809, 6829 comprise the majorityof the length of each cup 6810, 6830. More specifically, the length ofthe transition zone 6809, 6829 can be greater than the combined lengthof the respective entry zone and exit zone of each cup 6810, 6830. Thetransition zones 6809, 6829 can extend along the tapered or narrowingsection of each cup 6810, 6830. For example, each transition zone 6809,6829 can extend inward from the widest section of the respective cup6810, 6830 toward the bridge 6805.

FIG. 66 is a cross-sectional view of the distal forming cup 6830 takenalong line 66-66 in FIG. 62. This view is taken near the valley, ortrough, of the distal forming cup 6830. This valley, or trough, is alsothe transition between the entry zone forming surface 6831 and the exitzone forming surface 6832. In various instances, the transition betweenentry and exit zones does not occur at the valley, or trough, of thecup. FIG. 67 illustrates a cross-sectional view of the distal formingcup 6830 taken along line 67-67 in FIG. 62 which is located within theexit zone forming surface 6832 of the forming cup 6830. FIG. 64 is across-sectional view of the distal forming cup 6830 taken along line64-64 in FIG. 62, and FIG. 65 is a cross-sectional view of the distalforming cup 6830 taken along line 65-65 in FIG. 62, which are bothwithin the entry zone forming surface 6832 of the distal forming cup6830.

Referring primarily to FIGS. 64-67, the pair of cup sidewalls 6833 ofthe distal forming cup 6830 includes a first sidewall 6833 a and asecond sidewall 6833 b. The first and second sidewalls 6833 a, 6833 bare opposing sidewalls which extend toward each other fromlaterally-opposed sides of the distal forming cup 6830. The inflectionsurface, or bottom surface, 6834 of the distal forming cup 6830 ispositioned between the first and second sidewalls 6833 a, 6833 b. Thebottom surface 6834 of the distal forming cup 6830 is anentirely-curved, non-flat surface. In other words, the bottom surface6834 is devoid of flat, planar surfaces. The bottom surface 6834 candefine one or more radii of curvature. For example, at variouslongitudinal positions along the pocket axis 6803, the bottom surface6834 defines different radii of curvature. A tangent to the bottomsurface 6834 at the lateral center of the cup 6830 is parallel to theplanar surface 6807 along the length thereof.

In various instances, the curvature of the bottom surface 6834 can bedimensioned such that the staple leg does not travel along a flatsurface during the staple forming process. In such instances, the bottomsurface 6843 can encourage staples to form into a more planar formedconfiguration than staples formed with flat bottom surfaces, especiallywhen the staples are misaligned with the pocket axis 6803 duringformation. The curvature of the bottom surface 6843 can be dimensionedsuch that the bottom surface 6843 provides a plurality of contactsurfaces for the staple leg. For example, the radius of curvature of thebottom surface 6834 can be less than the radius of curvature of thestaple leg.

The cup sidewalls 6813, 6833 are entirely-curved, non-flat surfaces. Inother words, the cup sidewalls 6813, 6833 are devoid of flat, planarsurfaces. The sidewalls 6833 a, 6833 b define one or more radii ofcurvature. For example, at various longitudinal positions along thepocket axis 6803, the sidewalls 6833 a, 6833 b define different radii ofcurvature. The entirely-curved contours of the cup sidewalls 6813, 6833and the bottom surface 6834 can define curvilinear boundary surfaces ofthe cups 6810, 6830. The cups 6813, 6833 can be entirely-curved anddevoid of flat, planar surfaces.

The sidewalls 6833 a, 6833 b are oriented at an entry angle θ₂ relativeto the tissue-contacting surface 6807 at various transversecross-sections of the distal forming cup 6830. More specifically, atangent T to each sidewall 6833 a, 6833 b at the perimeter 6820 of thedistal forming cup 6830 is oriented at the angle θ₂ relative to thetissue-contacting surface 6807 in FIGS. 64-67. The entry angle θ₂ isconstant within the transition forming surface zone 6829 (FIGS. 62 and64) and along the majority of the length of the distal forming cup 6830.In various instances, the angle θ₂ can be between 55 degrees and 80degrees, for example. For instance, in FIGS. 64-67, the angle θ₂ is 80degrees. In other instances, the angle θ₂ can be less than 55 degrees ormore than 80 degrees. The sidewalls 6833 a, 6833 b are non-verticalsidewalls and, thus, the angle θ₂ of the tangent T along the perimeter6820 can be less than 90 degrees, for example.

A datum point at the transition between the sidewalls 6833 a, 6833 b andthe bottom surface 6834 is indicated for illustrative purposes in FIGS.64-67. For example, the curved boundary surface of the distal formingcup 6830 includes a datum point A at the transition between the sidewall6833 a and the bottom surface 6834. At each longitudinal position alongthe cup 6530, the first sidewall 6833 a and the second sidewall 6833 bdefine a sidewall radius of curvature 6843 and the bottom surface 6834defines a bottom radius of curvature 6844. The bottom radius ofcurvature 6844 can be different than the sidewall radius of curvature6843. The transition between radii of curvature at the datum point Acomprises a smooth, non-abrupt transition.

A datum line B is also depicted in FIGS. 64-67 for illustrativepurposes. The datum line B extends between the first datum point A andthe perimeter 6820 of the distal forming cup 6830. The datum line B isoriented at an angle θ₃ in FIGS. 64-67. The angle θ₃ changes along thelength of the distal forming cup 6830. In various instances, the angleθ₃ can be less than the angle θ₂ along the length of the distal formingcup 6830. The angle θ₃ can increase then decrease as the sidewalls 6833a, 6833 b extend inward toward the center C. For example, the angle θ₃can increase from the entry edge of the cup 6830 toward the transitionzone 6829, remain constant within the transition zone 6829, and decreasefrom the transition zone 6829 toward the exit edges of the cup 6830. Inthe depicted embodiment, the angle θ₃ is 45 degrees in FIG. 64, theangle θ_(3′) is 55 degrees in FIG. 65, the angle θ_(3″) is 70 degrees inFIG. 66, and the angle θ_(3′″) is 55 degrees in FIG. 67, for example.Though the angles θ₂ and θ₃ are constant within the transition zone 6829of the distal forming cup 6830, the radius of curvature and the lengthof the arcs defining the sidewalls 6833 a, 6833 b varies as the depthand width of the distal forming cup 6830 varies along the lengththereof.

The angle θ₂ relative to a tissue-contacting surface can comprise arelatively steep angle. For example, the angle θ₂ can be greater thanthe variable angle θ₃. The steepness of the angle θ₂ can encourage thestaple to form along the pocket axis. A constant angle θ₂ can encouragea misaligned staple leg to move from the perimeter toward the lateralcenter of the cup. In various instances, the angle θ₂ can be constantand steep within the exit zone, which can improve staple formationquality. Additionally or alternatively, the angle θ₂ can be constant inthe transition zone. As described herein, the depth of the pocket canvary along the length thereof. However, maintaining a constant angle θ₂can encourage a misaligned staple leg to move from the perimeter towardthe lateral center of the cup even in shallower regions of the cup.Furthermore, the maximum cup depth CD in certain anvils can vary betweenpockets in the anvil. For example, different depths can be utilized toform staples to different heights and/or to form staples driven bydrivers having different heights, as further described herein. In suchinstances, a constant angle θ₂ can encourage the staples formed by theshallower pockets to form along the pocket axis.

In certain instances, an anvil for a surgical end effector can includestaple forming pockets of different depths. For example, the depth ofstaple forming pockets can vary between rows of forming pockets and/orlongitudinally along the length of a row of forming pockets. Such depthdifferences can be selected to accommodate variations in thedisplacement of staple drivers within a staple cartridge during a staplefiring stroke, variations in the overdrive distance of the firedstaples, and/or the position of the anvil relative to the staplecartridge. Additionally or alternatively, depth differences betweenstaple forming pockets can correspond to different tissue gaps betweenstepped tissue compression surfaces on the anvil and/or a staplecartridge. For example, to form staples to the same formed height whenthe staples are driven by drivers having different lift lengths thatresult in different amounts of staple overdrive, a depth differencebetween staple forming pockets can be selected that corresponds to thedifferent stroke lengths and the different amounts of staple overdrive.In other instances, different depth staple forming pockets in an anvilcan be selected to form staples to different formed heights, which maybe desirable in certain instances to vary the compression of stapledtissue and/or to accommodate for variations in tissue thickness.

FIG. 67A is a partial negative view of various slices of a formingpocket of the forming pocket arrangement 6800. The dimensions of thevarious slices are labeled thereon. The slices are of only a singlesidewall of the forming pocket and are taken in planes along the formingpocket which are perpendicular to the tissue-contacting surface 6807 andthe pocket axis 6803. Each slice comprises a width “x”, a height “y”, anupper radius of curvature “ra”, and a lower radius of curvature “rb”.The width “x” is defined as the x-component of the distance between theperimeter 6820 of the forming pocket and the bottom radius of curvature6844 of the forming pocket. The height “y” is defined as the y-componentof the distance between the perimeter 6820 of the forming pocket and thebottom radius of curvature 6844 of the forming pocket. The upper radiusof curvature “ra” is defined as the radius of curvature of an upperportion of the sidewall. The lower radius of curvature “rb” is definedas the radius of curvature of an lower portion of the sidewall. Eachdimension includes a number indicating which slice the dimensioncorresponds to. For example, Slice 1 includes a width “x₁”, a height“y₁”, an upper radius of curvature “ra₁”, and a lower radius ofcurvature “rb₁”. FIG. 67B is a table 6850 comprising the dimensions ofthe Slices 1-12 of FIG. 67A, in at least one embodiment.

FIG. 67C is a cross-sectional view of the forming pocket arrangement6800 taken along the pocket axis 6803. FIG. 67C includes variousdimensions of the distal forming pocket 6830 of forming pocketarrangement 6800. The length of the forming pocket 6830 is 1.90 mm, forexample. The depth of the forming pocket 6830 is 0.50 mm, for example.In certain instances, the distal forming pocket 6830 comprises threeradii of curvature: an entry radius of curvature which is 1.40 mm, afirst exit radius of curvature which is 0.80 mm, and a second exitradius of curvature which is 0.10 mm, for example. The width of thebridge portion of the distal forming pocket 6830 is defined, in thisinstance, as the distance between the center of the forming pocketarrangement 6800 and the inner-most edge of the first exit radius ofcurvature (the edge of the first exit radius of curvature closest to thecenter of the forming pocket arrangement 6800) is 0.10 mm, for example.The bridge depth is 0.15 mm, for example.

Referring now to FIG. 70, a surgical end effector 7000 comprising ananvil 7001 and a staple cartridge 7060 having a plurality of staples7080 is depicted. The end effector 7000 is in a closed, or clamped,position. More specifically, the anvil 7001 can be pivoted relative tothe staple cartridge 7060 to move the end effector 7000 to the closedposition and clamp tissue between the anvil 7001 and the staplecartridge 7060. In other instances, the anvil 7001 can be fixed and thestaple cartridge 7060 can pivot relative to the anvil 7001 to move theend effector 7000 to the closed position and, in still other instances,both the anvil 7001 and the staple cartridge 7060 can be configured topivot to move the end effector 7000 toward the closed position.

In the closed position, a uniform tissue gap TG is defined between thestaple cartridge 7060 and the anvil 7001. In other words, the tissue gapTG is constant laterally across the end effector 7000. The staplecartridge 7060 includes a planar, or substantially flat, tissuecompression surface, or deck, 7062, and the anvil 7001 also includes aplanar, or substantially flat, tissue compression surface 7007. Neitherthe deck 7062 of the staple cartridge 7060 nor the tissue compressionsurface 7007 of the anvil 7001 includes a stepped surface havinglongitudinal steps between adjacent longitudinal portions. In otherinstances, as described herein, the deck of a staple cartridge and/orthe tissue compression surface of an anvil can include a steppedprofile.

The staple cartridge 7060 includes a staple cartridge body 7064 having alongitudinal slot 7065 and a plurality of staple cavities 7066 definedtherein. The slot 7065 extends along a central, longitudinal axis of thestaple cartridge 7060. Each staple cavity 7066 comprises an opening inthe deck 7062. The staple cavities 7066 are arranged in a plurality oflongitudinally extending rows 7068 including a first row, or outer row,7068 a, a second row, or intermediate row, 7068 b, and a third row, orinner row, 7068 c on each side of the slot 7065. In other instances, thestaple cartridge 7060 can have fewer than or more than six rows ofstaple cavities 7066. For example, a staple cartridge can have twostaple cavity rows on each side of the longitudinal slot 7065.

A staple 7080 is removably stored in each staple cavity 7066, and eachstaple 7080 is supported by a staple driver 7070. In various instances,a staple driver 7070 can support and fire more than one staple 7080. Forexample, a driver may be configured to simultaneously fire staples fromadjacent rows of staple cavities in a staple cartridge. The deck 7062includes cavity extenders 7061 that protrude from the deck 7062 towardthe tissue compression surface 7007 of the anvil 7001. The cavityextenders 7061 are positioned around at least a portion of the staplecavities 7066 and can guide the staples 7080 above the deck 7062. Thecavities extenders 7061 can also be configured to engage or grip tissueand/or support the staples 7080 and/or the drivers 7070 during firing.In other instances, the deck 7062 can be devoid of cavity extenders andcan comprise a smooth tissue-contacting surface, for example.

The staples 7080 in FIG. 70 are depicted in a formed configuration inwhich the staples 7080 fired from the cavities 7066 across the rows 7068a, 7068 b, 7068 c on both sides of the slot 7065 have been formed to thesame height H. Forming staples to a uniform height can tightly cinch thetissue and reduce bleeding therefrom.

The drivers 7070 are movably positioned in the cavities 7066. During afiring stroke, a firing member is configured to lift the drivers 7070toward the anvil 7001, which drives the staples 7080 supported on thedrivers 7070 into forming engagement with the anvil 7001. Each staple7080 is driven into forming contact with a staple forming pocketarrangement 7002, 7004 defined in the planar surface 7007 of the anvil7001. The staple forming pocket arrangements 7002, 7004 are arranged ina plurality of longitudinally extending rows 7003 including a first row,or outer row, 7003 a, a second row, or intermediate row, 7003 b, and athird row, or inner row, 7003 c on both lateral sides of the anvil 7001.Each row of staple cavities 7066 is aligned with a row 7003 of stapleforming pocket arrangements 7002, 7004. As described with respect tovarious staple forming pockets arrangements disclosed herein, the stapleforming pocket arrangements 7002, 7004 can each include a pair offorming pockets or cups, e.g., a proximal cup and a distal cup, and eachcup can be positioned to receive a staple leg when the staple 7080 isdriven into forming contact with the anvil 7001.

The anvil 7001 includes two different staple forming pocketarrangements. More specifically, the anvil 7001 includes a first stapleforming pocket arrangement 7002 comprising a first geometry and a secondstaple forming pocket arrangement 7004 comprising a second geometry. Thefirst staple forming pocket arrangements 7002 are aligned with theoutermost row 7068 a of staple cavities 7066 on both sides of the slot7065, and the second staple forming pocket arrangements 7004 are alignedwith the rows 7068 b, 7068 c of staple cavities 7066 on both sides ofthe slot 7065. The cups of the first staple forming pocket arrangement7002 define a cup depth CD₁ relative to the anvil planar surface 7007and the cups of the second staple forming pocket arrangement 7004 definea cup depth CD₂ relative to the anvil planar surface 7007. The cup depthCD₁ of the outer staple forming pocket arrangements 7002 is greater thanthe cup depth CD₂ of the inner staple forming pocket arrangements 7004.As a result, the deeper staple forming pockets of the first arrangement7002 are positioned laterally outboard of the shallower staple formingpockets of the second arrangement 7004, although any suitablearrangement can be used.

In various instances, the first staple forming pocket arrangements 7002can be the same as or similar to the staple forming pocket arrangement6800 (FIGS. 61-67) and the second staple forming pocket arrangements7004 can be the same as or similar to the staple forming pocketarrangement 6600 (FIGS. 55-61). Though the depth of the cups isdifferent between the first forming pocket arrangement 7002 and thesecond forming pocket arrangement 7004, the sidewalls of the cups canintersect the planar surface 7007 at the same angle, i.e., a tangent tothe sidewalls can be maintained at constant entry angle, along thelength of the cups in each arrangement 7002, 7004 or at least along themajority of the length of the cups in each arrangement 7002, 7004. Asdescribed herein, a steep constant angle sidewall is configured tofacilitate planar formation of the staples 7080, including staples thatare misaligned with the central axis of the arrangement 7002, 7004.

In the fired position depicted in FIG. 70, the staples 7080 have beenoverdriven with respect to the staple cartridge body 7064. Morespecifically, the staple-supporting surface of each driver 7070 has beendriven past the staple cartridge body 7064 such that the staples 7080are completely removed from the cartridge body 7064 during firing. Whenoverdriven, the cradle, or bottommost surface, of each staple 7080 ispositioned above the deck 7062 and/or above the cavity extenders 7061protruding from the deck 7062. The overdrive feature of the drivers 7070can be configured to fully eject the fired staples 7080 from the staplecartridge 7060 and to facilitate the release of stapled tissue from theend effector 7000, for example. Stated another way, the overdrivefeature of the drivers 7070 can push the tissue away from the deck 7067

In various instances, different staples can be overdriven by differentamounts. For example, the staples 7080 fired from the outer rows 7068 aof staple cavities 7066 are overdriven a first distance D₁ relative tothe deck surface 7062 and the staples 7080 fired from the intermediateand inner rows 7068 b, 7068 c of staple cavities 7066 are overdriven asecond distance D₂ relative to the deck surface 7062. The distances D₁and D₂ in FIG. 70 are the distances between the cradle of the staples7080 and the planar deck surface 7062. In other instances, the overdrivedistance can be measured between the support surfaces of the staplecradles and the uppermost surface of the adjacent cavity extenders 7061.

To achieve the different overdrive distances D₁ and D₂ in FIG. 70, thestroke length of the drivers 7070 can be different. For example, thefiring element can be configured to lift the drivers 7070 supportingstaples 7080 in the outer rows 7068 a a first distance and the drivers7070 supporting the staples 7080 in the inner rows 7068 b, 7068 c asecond distance. In certain instances, the geometry of the sled can beselected to control the different stroke lengths of the drivers 7070.Additionally or alternatively, the geometry of the drivers 7070, such asthe driver's height, for example, can be selected to control thedifferent overdrive distances.

For each formed staple 7080 in FIG. 70, the sum of the tissue gap andthe cup depth is equal to the sum of the overdrive distance and thestaple height. For example:TG+CD₁ =D ₁ +H;andTG+CD₂ =D ₂ +H.Stated differently, for each formed staple, the height of the staple Hequals the tissue gap TG plus the cup depth CD minus the overdrivedistance D.H=TG+CD₁ −D ₁;andH=TG+CD₂ −D ₂.In instances in which the height of the staple H and the tissue gap TGare constant laterally across the end effector 7000, as depicted in FIG.70, the different cup depths correspond to different overdrivedistances. For example, to ensure the anvil 7001 is compatible with thestaple cartridge 7060, the staple forming pocket arrangements 7002, 7004and cup depths CD₁, CD₂ thereof can be selected to accommodate thedifferent overdrive distances D₁, D₂. For example, the differencebetween the cup depth CD₁ and the cup depth CD₂ can be configured toaccommodate the difference in overdrive distances D₁ and D₂:CD₁−CD₂ =D ₁ −D ₂.More specifically, if the difference between the overdrive distances D₁and D₂ is 0.38 millimeters, for example, the difference between the cupdepths CD₁ and CD₂ can also be 0.38 millimeters. In certain instances,the difference in overdrive distances and cup depths can be between 0.2millimeters and 1 millimeter, for example. The corresponding differencebetween the overdrive distances D₁ and D₂ and the cup depths CD₁ and CD₂is configured to form the staples 7080 to the same formed height Hlaterally across the end effector 7000. Regardless of the cup depth, thesidewalls of the cups can be designed to intersect the tissuecompression surface 7007 of the anvil 7001 at a constant angle toencourage the planar formation of the staples 7080, including misalignedstaples, as further described herein.

In certain instances, surgical instruments and/or subassemblies thereofcan be modular. Different types of staple cartridges can be compatiblewith more than one anvil and/or different types of anvils can becompatible with more than one staple cartridge. For example, the staplecartridge 7060, which is compatible with the anvil 7001 having a flattissue compression surface 7007 (see, e.g. FIG. 70) can also becompatible with a stepped anvil. An end effector that includes thestaple cartridge 7060 and a compatible stepped anvil can define alaterally variable tissue gap TG; however, such an end effector canstill be configured to form staples to a constant formed height. In suchinstances, the different overdrive distances D₁ and D₂ can correspond todifferent heights of an anvil's stepped tissue compression surface.

Referring now to FIG. 71, an end effector 7100 is depicted with thestaple cartridge 7060 and an anvil 7101. The end effector 7100 is in aclosed or clamped position. In use, the anvil 7101 can be pivotedrelative to the staple cartridge 7060 to move the end effector 7100 tothe closed position and clamp tissue between the anvil 7101 and thestaple cartridge 7060. In other instances, the anvil 7101 can be fixedand the staple cartridge 7060 can pivot relative to the anvil 7101 tomove the end effector 7100 to the closed position and, in still otherinstances, both the anvil 7101 and the staple cartridge 7060 can beconfigured to pivot the end effector 7100 toward the closed position.

The anvil 7101 includes a stepped tissue compression surface 7107 havinglongitudinal steps between adjacent longitudinal portions. Morespecifically, the anvil 7101 includes a plurality of longitudinalportions 7110 including a first portion, or outer portion, 7110 a and asecond portion, or inner portion, 7110 b on each lateral side of theanvil 7101. A step 7112 is positioned between the outer portion 7100 aand the inner portion 7100 b. The step 7112 extends parallel to rows ofstaple forming pocket arrangements 7102 defined in the surface 7107 andextends along an axis positioned intermediate adjacent rows of stapleforming pocket arrangements 7102.

The step 7112 comprises a height H_(step), which corresponds to theheight difference between the first longitudinal portion 7110 a and thesecond longitudinal portion 7110 b of the tissue compression surface7107. Because the staple cartridge 7060 includes a non-stepped deck7062, the height H_(step) corresponds to the variation in tissue gapbetween the staple cartridge 7060 and the anvil 7101 when the endeffector 7100 is in the closed position. A first tissue gap TG₁ isdefined between the first portion 7110 a and the staple cartridge 7060and a second tissue gap TG₂ is defined between the second portion 7110 band the staple cartridge 7060. The tissue gap TG₁ is greater than thetissue gap TG₂. It can be desirable to provide greater tissuecompression adjacent to the slot 7065 and/or along the inner portion7110 b of the anvil 7101 than along the lateral sides of the endeffector 7100. In other instances, the anvil 7101 can include additionallongitudinal portions having steps therebetween and, in such instances,may define additional, different tissue gaps when the end effector 7100is in the closed position.

The staples 7080 in FIG. 71 are depicted in the formed configuration inwhich the staples 7080 fired from the rows 7068 a, 7068 b, 7068 c ofstaple cavities 7066 on both sides of the slot 7065 have been formed tothe same height H. During a staple firing stroke, a firing member isconfigured to lift the drivers 7070 toward the anvil 7101, which drivesthe staples 7080 supported on the drivers 7070 into forming engagementwith the anvil 7101. More specifically, each staple 7080 is driven intoforming contact with one of the staple forming pocket arrangements 7102defined in the tissue compression surface 7107 of the anvil 7101. Thestaple forming pocket arrangements 7102 are arranged in a plurality oflongitudinally extending rows 7103 including a first row, or outer row,7103 a, a second row, or intermediate row, 7103 b, and a third row, orinner row, 7103 c on both sides of the anvil 7101. The firstlongitudinal portion 7110 a includes the first row 7103 a, and thesecond longitudinal portion 7110 b includes the second and third rows7103 b, 7103 c. Each row 7068 of staple cavities 7066 is aligned with arow 7103 of staple forming pocket arrangements 7102. As described withrespect to the various staple forming pockets arrangements disclosedherein, each staple forming pocket arrangement 7102 includes a pair offorming pockets or cups, e.g., a proximal cup and a distal cup, and eachcup is positioned to receive a staple leg when the staple 7080 is driveninto forming contact with the anvil 7101.

The staple forming pocket arrangements 7102 define a cup depth CDrelative to the tissue compression surface 7107. In various instances,the staple forming pocket arrangements 7102 are the same as or similarto the staple forming pocket arrangement 6600 (FIGS. 55-60). In suchinstances, the sidewalls of the cups can intersect the tissuecompression surface 7107 at a constant angle, i.e., a tangent to thesidewalls can be maintained at constant entry angle, along the length ofthe cups or at least along the majority of the length of the cups. Asteep constant angle sidewall along the length of the cups is configuredto facilitate planar formation of the staples 7080, including staplesthat are misaligned with the central axis of the staple formingarrangement 7102.

For each formed staple 7080 in FIG. 71, the sum of the tissue gap andthe cup depth is equal to the sum of the overdrive distance and thestaple height. For example:TG₁+CD=D ₁ +H;andTG₂+CD=D ₂ +H.Stated differently, for each formed staple, the height of the staple Hequals the tissue gap TG plus the cup depth CD minus the overdrivedistance D.H=TG₁+CD−D ₁;andH=TG₂+CD−D ₂.In instances in which the height H of the staple and the cup depth CDare constant laterally across the end effector 7100, as depicted in FIG.71, the height of the tissue compression surface 7107 can vary, i.e.,define a stepped profile, which corresponds to the different overdrivedistances. For example, the difference between the tissue gap TG₁ andthe tissue gap TG₂ can be configured to accommodate the difference inoverdrive distances D₁ and D₂:TG₁−TG₂ =D ₁ −D ₂.Stated differently, the height H_(step) of the step 7112 between thelongitudinal portions 7110 a, 7110 b can be equal to the difference inoverdrive distances D₁ and D₂:H _(step) =D ₁ −D ₂.For example, if the difference between the overdrive distances D₁ and D₂is 0.38 millimeters, the height H_(step) of the step 7112 can also be0.38 millimeters, for example. In certain instances, the difference inoverdrive distances and the tissue gap can be between 0.2 millimetersand 1 millimeter. Corresponding difference between the overdrivedistances D₁ and D₂ and the height of the longitudinal portions 7110 a,7110 b can be configured to form the staples 7080 to the same formedheight H laterally across the end effector 7100.

Above certain threshold loads, the anvil 7101 may be prone to bendingalong the step 7112 such that the tissue gap along the lateral sides ofthe anvil 7101 is greater than the tissue gap TG₁ depicted in FIG. 71.As a result, the anvil 7001 (FIG. 70) may be stiffer than the anvil 7101because the anvil 7001 comprises a planar, or non-stepped, tissuecompression surface 7007. The anvil 7001 can be more rigid and, thus,less prone to bending and/or deflecting when subjected to highcompression loads during clamping and/or firing.

In various instances, it can be desirable to utilize an anvil having aplanar, or non-stepped, tissue compression surface, such as the anvil7001, to minimize deflection of the anvil along the lateral sidesthereof. In certain instances, a variable tissue gap can also bedesirable to control tissue flow and/or the quantity of tissuecompressed and ultimately captured by the end effector. For example, asmaller outer tissue gap and larger inner tissue gap can allow the endeffector to capture a greater quantity of tissue adjacent to thecutline, which may improve hemostasis. The smaller outside tissue gapmay improve control over tissue flow and ensure that the lateral sidesof the end effector effectively grip and engage the target tissue.Moreover, the larger inside tissue gap may allow the end effector tocapture a larger, e.g., thicker, piece of tissue.

An exemplary variable tissue gap end effector 7200 is depicted in FIG.72. The end effector 7200 includes the anvil 7001 having a planar, ornon-stepped, tissue compression surface 7007 (see also FIG. 70) and astaple cartridge 7260 having a stepped deck 7262. Though the tissue gapvaries laterally across the end effector 7200, the end effector 7200 canbe configured to form staples 7280 to a constant formed height. Forexample, different staple overdrive distances can correspond to thedifferent tissue gaps and/or different staple forming arrangementshaving different cup depths, as further described herein.

Referring still to FIG. 72, the end effector 7200 is in a closed orclamped position. In use, the anvil 7001 can be pivoted relative to thestaple cartridge 7260 to move the end effector 7200 to the closedposition and clamp tissue between the anvil 7001 and the staplecartridge 7260. In other instances, the anvil 7001 can be fixed and thestaple cartridge 7260 can pivot relative to the anvil 7001 to move theend effector 7200 to the closed position and, in still other instances,both the anvil 7001 and the staple cartridge 7260 can be configured topivot to move the end effector 7200 toward the closed position.

The staple cartridge 7260 includes a staple cartridge body 7264 having alongitudinal slot 7265 and a plurality of staple cavities 7266 definedtherein. Staples 7280 are moveably positioned in the staple cavities7266. The slot 7265 can extend along a central, longitudinal axis of thestaple cartridge 7260. Each staple cavity 7266 comprises an opening inthe deck 7262. The staple cavities 7266 are arranged in a plurality oflongitudinally extending rows 7268 including a first row, or outer row,7268 a, a second row, or intermediate row, 7268 b, and a third row, orinner row, 7268 c on each side of the slot 7265. In other instances, thestaple cartridge 7260 can have fewer than or more than six rows ofstaple cavities 7266. For example, a staple cartridge can have twostaple cavity rows on each side of a longitudinal slot.

Each staple 7280 is supported by a staple driver 7270. In variousinstances, a staple driver 7270 can support and fire more than onestaple 7280. For example, a driver may be configured to fire staplesfrom adjacent rows of staple cavities in a staple cartridge. The deck7262 includes cavity extenders 7261 that protrude from the deck 7262toward the tissue compression surface 7007 of the anvil 7001. The cavityextenders 7261 are positioned around at least a portion of the staplecavities 7266 and can guide the staples as they are ejected from thestaple cavities 7266. The cavities extenders 7261 may also be configuredto engage or grip tissue and/or support the staples 7280 and/or thedrivers 7270 during firing, for example. In other instances, the deck7262 can be devoid of cavity extenders and can comprise a smoothtissue-contacting surface, for example.

The staples 7280 in FIG. 72 are depicted in a formed configuration inwhich the staples 7280 fired from the cavities 7266 across the rows 7268a, 7268 b, 7268 c on both sides of the slot 7265 have been formed to thesame height H. In certain instances, it can be advantageous to formstaples across multiple rows to tightly cinch the tissue and reducebleeding therefrom.

The drivers 7270 are movably positioned in the cavities 7266. During afiring stroke, a firing member is configured to lift the drivers 7270toward the anvil 7001, which drives the staples 7280 supported on thedrivers 7070 into forming engagement with the anvil 7001. Each staple7280 is driven into forming contact with a staple forming pocketarrangement 7002, 7004. Each row 7268 of staple cavities 7266 is alignedwith a row 7003 of staple forming pocket arrangements 7002, 7004. Thefirst staple forming pocket arrangements 7002 are aligned with theoutermost row 7268 a of staple cavities 7266 on each side of the slot7265, and the second staple forming pocket arrangements 7004 are alignedwith the innermost rows 7268 b, 7268 c of staple cavities 7266 on eachside of the slot 7265.

The staple cartridge 7260 includes a stepped deck 7262 havinglongitudinal steps between adjacent longitudinal portions. Morespecifically, the staple cartridge 7260 includes a plurality oflongitudinal portions 7263 including a first portion, or outer portion,7263 a and a second portion, or inner portion, 7263 b on each side of aslot 7260. A step 7267 is positioned between the outer portion 7263 aand the inner portion 7263 b. The step 7267 extends parallel to rows7268 of staple cavities 7266 defined in the deck 7262 and extends alongan axis positioned intermediate adjacent rows 7268 of staple cavities7266.

The step 7267 comprises a height H_(step), which corresponds to theheight difference between the first longitudinal portion 7263 a and thesecond longitudinal portion 7263 b of the deck 7262. Moreover, becausethe anvil 7001 includes a non-stepped tissue compression surface 7007,the height H_(step) corresponds to the variation in tissue gap betweenthe staple cartridge 7260 and the anvil 7001 when the end effector 7200is in the closed position. A first tissue gap TG₁ is defined between thefirst portion 7263 a and the anvil 7001 and a second tissue gap TG₂ isdefined between the second portion 7263 b and the anvil 7001. The tissuegap TG₂ is greater than the tissue gap TG₁. It is desirable in certaininstances to provide greater tissue compression adjacent to the lateralsides of the end effector 7200 than along a central inner portion of theend effector 7200, as further described herein. In other instances, thestaple cartridge 7260 can include additional longitudinal portionshaving steps therebetween and, in such instances, may define additional,different tissue gaps when the end effector 7200 is in the closedposition.

In the fired positions depicted in FIG. 72, the staples 7280 have beenoverdriven with respect to the staple cartridge body 7264. Morespecifically, the staple-supporting surface of each driver 7270 has beendriven past the staple cartridge body 7264 such that the staples 7280are completely removed from the cartridge body 7264 during firing. Thecradle, or bottommost surface, of each staple 7280 is positioned abovethe deck 7262. The cradles of certain staples 7280 are also positionedabove the cavity extenders 7261 protruding from the deck 7262 and thecradles of other staples 7280 are positioned below and/or flush with thecavity extenders 7261. The overdrive feature of the drivers 7270 can beconfigured to fully detach the fired staples 7280 from the staplecartridge 7260 and to facilitate the release of stapled tissue from theend effector 7200.

In various instances, different staples can be overdriven by differentamounts. For example, the staples 7280 fired from the outer rows 7268 aof staple cavities 7266 are overdriven a first distance D₁, the staples7280 fired from the intermediate rows 7268 b of staple cavities 7266 areoverdriven a second distance D₂ relative to the cartridge body 7264, andthe staples 7280 fired from the inner rows 7268 c of staple cavities7266 are overdriven a third distance D₃ relative to the cartridge body7264. The distances D₁, D₂, and D₃ in FIG. 72 are the distances betweenthe cradle of the staples 7280 and the adjacent portion of the decksurface 7262.

To achieve the different overdrive distances D₁, D₂, and D₃ in FIG. 72,the stroke length of the drivers 7270 can be different. For example, thefiring element can be configured to lift the drivers 7270 supportingstaples 7280 in the outer rows 7268 a a first distance, to lift thedrivers 7070 supporting the staples 7280 in the intermediate row 7268 ba second distance, and to lift the drivers 7270 supporting the staples7280 in the inner rows 7268 c a third distance. In certain instances,the geometry of the firing element can be selected to control thedifferent stroke lengths of the drivers 7270. Additionally oralternatively, the geometry of the drivers 7270, such as the driver'sheight, for example, can be selected to control the different overdrivedistances. The different overdrive distances D₁, D₂, and D₃ in FIG. 72can also be controlled by the different heights of the stepped deck7262.

As described herein with respect to the end effector 7000 (FIG. 70),when the tissue gap is constant between rows of staples, different cupdepths can be configured to accommodate for variations in overdrivedistance such that the staples are formed to the same formed height. Forexample, referring again to FIG. 72, the tissue gap TG₁ is constantbetween the first and second rows 6268 a, 6268 b of staple cavities 6266and, in such instances, the different cup depths CD₁ and CD₂ areconfigured to accommodate for the variations in overdrive distances D₁and D₂. Moreover, as described with respect to the end effector 7100(FIG. 71) when the tissue gap varies between rows of staples, the tissuegap differential can correspond to variations in overdrive distance suchthat staples are formed to the same formed height. For example,referring again to FIG. 72, the height H_(step) of the step 7267corresponds to the difference between the overdrive distances D₂ and D₃.

In various instances, the staple cartridge 7260 can also be compatiblewith an anvil having a stepped tissue compression surface, such as theanvil 7101 (FIG. 71). In such instances, the different overdrivedistances D₁, D₂, and D₃ can correspond to different tissue gaps betweenthe anvil's stepped tissue compression surface 7107 and the staplecartridge's stepped deck 7262. An end effector 7300 that includes thestaple cartridge 7260 and the anvil 7101 is depicted in FIG. 73. Asfurther described herein, the end effector 7300 is configured to formstaples to a constant formed height across multiple rows.

Owing to the two stepped surfaces 7107 and 7262 in FIG. 73, the endeffector 7300 defines a plurality of tissue gaps between the anvil 7101and the staple cartridge 7260. A first tissue gap TG₁ is defined betweenthe first portion 7263 a of the deck 7262 and the first portion 7110 aof the tissue compression surface 7107, a second tissue gap TG₂ isdefined between the first portion 7263 a of the deck 7262 and the secondportion 7110 b of the tissue compression surface 7107, and a thirdtissue gap TG₃ is defined between the second portion 7263 b of the deck7262 and the second portion 7110 b of the tissue compression surface7107. The outer rows 7268 a of staple cavities 7266 and the outer rows7103 a of staple forming pockets 7102 are aligned with the first tissuegap TG₁, the intermediate rows 7268 b of staple cavities 7266 and theintermediate rows 7103 b of staple forming pockets 7102 are aligned withthe second tissue gap TG₂, and the inner rows 7268 c of staple cavities7266 and the inner rows 7103 c of staple forming pockets 7102 arealigned with the third tissue gap TG₃. As described with respect to theend effector 7100 (FIG. 71), when the tissue gap varies between rows ofstaples, the tissue gap differential can correspond to variations inoverdrive distance such that staples are formed to the same formedheight. For example, referring again to FIG. 73, the height H_(step) ofthe anvil step 7112 corresponds to the difference between the overdrivedistances D₁ and D₂ and the height H_(step) of the cartridge step 7267corresponds to the difference between the overdrive distances D₂ and D₃.

As described herein, a surgical tool assembly can include a shaftportion and an articulatable end effector portion. For example, anarticulation assembly can be positioned intermediate the shaft portionand the end effector portion, and the articulation assembly can enablethe end effector portion to articulate at an articulation joint relativeto the shaft portion. Various articulation assemblies are furtherdescribed herein and in U.S. patent application Ser. No. 15/019,245,filed Feb. 9, 2016, entitled SURGICAL INSTRUMENTS WITH CLOSURE STROKEREDUCTION ARRANGEMENTS, the entire disclosure of which is herebyincorporated by reference herein.

An exemplary surgical tool assembly 8000 having an articulation joint8200 is depicted in FIGS. 74-77. The surgical tool assembly 8000includes a shaft 8010 and an end effector 8100. The shaft 8010 includesa closure tube assembly 8040. The closure tube assembly 8040 is similarin many respects to the closure tube assembly 140 (see, e.g. FIG. 2),for example, which is further described herein. The shaft 8010 alsoincludes an articulation drive system 8201 configured to articulate theend effector 8100 relative to the shaft 8010. The articulation joint8200 is positioned intermediate the shaft 8010 and the end effector 8100such that articulation motions generated by the articulation drivesystem 8201 articulate the end effector 8100 about an articulation axisB-B (FIGS. 75-77) relative to the shaft 8010.

The articulation drive system 8201 includes an articulation rod 8202including a distal end 8204. The articulation drive system 8201 alsoincludes an articulation link 8206 comprising a proximal end 8208coupled to the distal end 8204 of the articulation rod 8202. Thearticulation rod 8202 extends longitudinally through the shaft portion8010. In at least one instance, the articulation rod 8202 can becollinear with a central, longitudinal axis L (FIGS. 75-77) of the shaftportion 8010 that extends through the articulation axis B-B, althoughthe articulation rod 8202 can be offset from the longitudinal axis L inother embodiments. The distal end 8204 of the articulation rod 8202includes an extension 8205 extending laterally relative to the central,longitudinal axis L. For example, the extension 8205 extends away fromthe central, longitudinal axis L. As further described herein, thelateral offset of the extension 8205 relative to the axis L isconfigured to obtain the desired angular orientation of the articulationlink 8206. The articulation rod 8202 is configured to move axially alongthe central, longitudinal axis L to affect the articulation motions ofthe end effector 8100. More specifically, displacement of thearticulation rod 8202 in the distal direction (DD) is configured toarticulate the end effector 8100 clockwise, and displacement of thearticulation rod 8202 in the proximal direction (PD) is configured toarticulate the end effector 8100 counterclockwise, for example.

The end effector 8100 is articulatable between a first fully articulatedconfiguration and a second fully articulated configuration. The firstfully articulated configuration can correspond to the full extent ofclockwise rotation, for example, and the second fully articulatedconfiguration can correspond to the full extent of counterclockwiserotation, for example. An unarticulated, or linear, configuration of theend effector 8100 can be positioned intermediate the first fullyarticulated configuration and the second fully articulated position. Invarious instances, the unarticulated configuration can be equidistantbetween the first and second fully articulated configurations. In otherinstances, based on the geometry of the end effector 8100 and the shaft8010, a greater degree of articulation can be permitted in onerotational direction. The end effector 8100 can be articulatable througha range of motion comprising at least 120 degrees, for example. In otherinstances, the end effector 8100 can be configured to articulate throughless than 120 degrees. For instance, the end effector 8100 can beconfigured to articulate about 90 degrees.

The articulation link 8206 is a crosslink, which is similar in certainrespects to the crosslink 1237 (FIG. 10), for example. The articulationlink 8206 is angularly oriented relative to the central, longitudinalaxis L. More specifically, the articulation link 8206 traverses thecentral, longitudinal axis L such that the proximal end 8208 of thearticulation link 8206 is positioned on a first side of the central,longitudinal axis L, and a distal end 8210 of the articulation link 8206is positioned on a second, opposite side of the central, longitudinalaxis L. In various instances, the angular orientation of thearticulation link 8206 can be configured to improve the mechanicaladvantage of the articulation drive system 8201. As the articulation rod8202 moves axially relative to the central, longitudinal axis L, thearticulation link 8206 is also displaced relative to the central,longitudinal axis L. For example, referring to FIGS. 75-77, as thearticulation joint 8200 is moved from an unarticulated configuration(FIG. 75) to a first articulated configuration (FIG. 76) and to a secondarticulated configuration (FIG. 77), the articulation rod 8202 and thearticulation link 8206 are displaced distally. As further describedherein, the first articulated configuration corresponds to a partiallyarticulated configuration and the second articulated configurationcorresponds to a fully articulated configuration of the surgical toolassembly 8000.

In certain instances, the articulation drive system 8201 may not includethe articulation link 8206. For example, the articulation rod 8202 canbe pivotably coupled to the end effector 8100. In certain instances, thedistal end portion of the articulation rod 8202 can define a contourand/or offset such that the distal end of the articulation rod 8202 islaterally offset from the proximal end and/or from the central,longitudinal axis L.

Referring still to FIGS. 74-77, the distal end 8210 of the articulationlink 8206 is pivotably coupled to the end effector portion 8100 of thesurgical tool assembly 8000 at a pivot joint 8211. For example, thedistal end 8210 is coupled to a proximal portion, or extension, 8103 ofthe end effector's elongate channel or retainer portion 8102 at a pivotaxis A-A (FIGS. 75-77) through the pivot joint 8211. Owing to theorientation of the articulation link 8206, the pivot axis A-A islaterally offset from the central, longitudinal axis L and from thearticulation axis B-B. The distal end 8210 of the articulation link 8206is coupled to the proximal extension 8103 such that the pivot axis A-Aextends through the proximal extension 8103.

As the articulation rod 8202 and the articulation link 8206 are moved,e.g. pushed, in the distal direction (DD), the elongate channel 8102 ispivoted in the clockwise direction at the pivot axis A-A. In variousinstances, the end effector 8100 can encounter resistance to thearticulation thereof and the articulation link 8206 can be subjected toa compressive load as the articulation drive system 8201 seeks toovercome the resistance. In certain instances, when exposed to a loadabove a threshold load, the articulation bar 8202 and/or thearticulation link 8206 may be prone to bending, buckling, and/or backingup from the desired articulated position. Stated another way, thearticulation link 8206 can be susceptible to lateral bowing underincreased compressive loads. To counter or resist bowing and/orde-articulation of the compressed articulation bar 8202 and/orarticulation link 8206 under high compressive loads, the articulationsystem 8201 can include a reinforcement or anti-backup feature.

A reinforcement feature 8220 is depicted in FIGS. 74-77. Thereinforcement feature 8220 includes a brace 8106 on the end effector8100, which is operably configured to engage a recess or notch 8226 inthe articulation link 8206 in certain instances. The brace 8106 isdisengaged from the recess 8226 during the majority of the articulationmotion (see FIGS. 74-76); however, in the fully articulatedconfiguration of FIG. 77, the brace 8106 is received within the recessor pocket 8226, and portions of the brace 8106 are in abutting contactwith the sidewalls of the recess 8226. The brace 8106 comprises a postthat protrudes from the proximal end of the elongate channel 8102 andthe recess 8226 defines a pocket that is aligned with the brace 8106such that the brace 8226 moves into the pocket when the end effector8100 is articulated into its fully articulated configuration (FIG. 77).In such instances, the brace 8106 provides a stopping surface thatprevents further clockwise articulation of the end effector 8100 beyondthe fully articulated configuration.

Moreover, in the fully articulated configuration of FIG. 77, the brace8106 is configured to exert a counter-bowing and anti-backup force onthe articulation link 8206. More specifically, when a force is appliedto the end effector 8100, such as an externally-applied force opposingthe articulation motion of the articulation drive system 8201, the moreengagement between the recess 8226 and the brace 8106 is configured toresist de-articulation and/or bowing of the articulation link 8206. Forexample, the recess 8226 can apply a resistive, anti-backup force to thebrace 8016 in response to a de-articulation force being applied to thefully articulated end effector 8100.

In various instances, the reinforcement feature 8220 can include atleast one pair of opposing planar surfaces or “flats” to transfer forcesbetween the brace 8106 and the recess 8226. For example, the recess 8226can define an inner surface having at least one flat or planar surfaceand the brace 8106 can define an outer surface having at least one flator planar surface. The planar surface(s) can be complementary such thatthey are positioned in abutting contact when the end effector 8100 is inthe fully articulated configuration. For example, the recess 8226 canfit around portions of the brace 8106 like a wrench fits on the head ofa bolt. Abutting planar surfaces are configured to provideforce-transfer surfaces for the reinforcement feature 8220 and counterrotation of the brace 8106 within the recess 8226. The brace 8106 andthe recess 8226 have asymmetric profiles. However, the brace 8106 andthe recess 8226 can have symmetric outer profiles in other instances.

Referring primarily to FIG. 77A, a detail view of the reinforcementfeature 8220 of FIG. 77 is depicted. The recess 8226 includes an innersurface 8228 having a plurality of planar surface 8230 a, 8230 b, 8230c. Moreover, the brace 8106 includes an outer surface 8108 having aplurality of complementary planar surfaces 8110 a, 8110 b, 8210 b. Theplanar surface(s) 8230 a, 8230 b of the recess 8226 can abut thecorresponding planar surface(s) 8210 a, 8210 b of the brace 8226 to holdthe brace 8106 within the recess 8226. Moreover, when the brace 8106 isreceived within the recess 8226, the planar surfaces can be oriented toresist de-articulation and/or and exert counter-bowing forces on thearticulation link 8206. In various instances, the inner surface 8228 ofthe recess 8226 and the outer surface 8108 of the brace 8106 can alsoinclude contoured and/or rounded surfaces adjacent to and/orintermediate the planar surfaces.

In various instances, the articulation system 8201 can include aplurality of reinforcement features 8220. For example, the articulationsystem 8201 can include a recess similar to the recess 8226 toward theproximal end 8208 of the articulation link 8206. Such a recess can beconfigured to engage a grounding feature on the end effector 8100 and/orprovide a positive stopping surface when the end effector 8100 is fullyarticulated in a counterclockwise direction, for example.

EXAMPLES Example 1

An end effector that comprises a staple cartridge that comprises astaple that comprises a leg. The end effector further comprises an anvilthat comprises a tissue compression surface, wherein a plurality ofpockets are defined in the tissue compression surface. The plurality ofpockets comprises a pocket that comprises a cup configured to form theleg. The cup comprises a boundary surface. The boundary surfacecomprises a perimeter, a depth profile defining the depth of the cupalong the length of the cup, a first curved sidewall extending from theperimeter toward the depth profile, and a second curved sidewallextending from the perimeter toward the depth profile. The first curvedsidewall and the second curved sidewall intersect the perimeter at aconstant angle along a majority of the length of the cup.

Example 2

The end effector of Example 1, wherein the boundary surface is devoid offlat surfaces.

Example 3

The end effector of Examples 1 or 2, wherein the constant angle isbetween 55 degrees and 80 degrees.

Example 4

The end effector of Examples 1, 2, or 3, wherein the boundary surfacefurther comprises a bottom surface intermediate the first curvedsidewall and the second curved sidewall. The first curved sidewallcomprises a first radius of curvature at a first cross-sectionallocation. The bottom surface comprises a second radius of curvature atthe first cross-sectional location. The second radius of curvature isdifferent than the first radius of curvature.

Example 5

The end effector of Example 4, wherein the bottom surface comprises avariable radius of curvature along the length thereof.

Example 6

An end effector that comprises a staple cartridge that comprises astaple that comprises a leg. The end effector further comprises an anvilthat comprises a planar surface, wherein a plurality of pockets aredefined in the planar surface. The plurality of pockets comprises apocket that comprises a cup configured to form the leg. The cupcomprises a boundary surface. The boundary surface comprises aperimeter, a depth profile defining the depth of the cup along thelength of the cup, and a plurality of curvatures traversing theperimeter and the depth profile. Each curvature comprises a first arcintersecting the perimeter and comprising a first radius of curvature,wherein a tangent to each first arc at the perimeter is oriented at anangle.

Example 7

The end effector of Example 6, wherein each curvature comprises a secondarc that comprises a second radius of curvature. The second radius ofcurvature is different than the first radius of curvature.

Example 8

The end effector of Examples 6 or 7, wherein the angle is between 55degrees and 80 degrees.

Example 9

The end effector of Examples 6, 7, or 8, wherein the boundary surfacefurther comprises a first sidewall extending from the perimeter towardthe depth profile, a second sidewall extending from the perimeter towardthe depth profile, and an inflection surface extending intermediate thefirst sidewall and the second sidewall. The inflection surface is devoidof flat surfaces.

Example 10

The end effector of Examples 6, 7, 8 or 9, wherein the depth of the cupvaries along the length thereof.

Example 11

An end effector that comprises a staple cartridge that comprises astaple that comprises a leg. The end effector further comprises an anvilthat comprises a planar surface, wherein a plurality of pockets aredefined in the planar surface. The plurality of pockets comprises apocket that comprises a cup configured to form the leg of the staple.The cup comprises a boundary surface. The boundary surface comprises aperimeter, a depth profile defining the depth of the cup along thelength of the cup, and a plurality of longitudinally-offset profilecurvatures intersecting the perimeter and the depth profile. The profilecurvatures intersect the perimeter at a first angle.

Example 12

The end effector of Example 11, wherein the end effector is movablebetween an open position and a clamped position. The leg is aligned withthe cup when the end effector is in the clamped position.

Example 13

The end effector of Examples 11 or 12, wherein the plurality of profilecurvatures comprises a first curvature and a second curvature. Theperimeter of the cup extends around a staple entry zone, a staple exitzone, and a transition zone intermediate the staple entry zone and thestaple exit zone. The first curvature and the second curvature intersectthe perimeter in the transition zone.

Example 14

The end effector of Example 13, wherein the plurality of profilecurvatures further comprises a third curvature intersecting theperimeter at a second angle in the staple entry zone. The second angleis different than the first angle.

Example 15

The end effector of Example 13, wherein the plurality of profilecurvatures further comprises a third curvature intersecting theperimeter at a second angle in the staple exit zone. The second angle isdifferent than the first angle.

Example 16

The end effector of Example 13, wherein the boundary surface furthercomprises a first sidewall extending from a first lateral side of thecup, a second sidewall extending from a second lateral side of the cup,and a bottom surface. The first sidewall and the second sidewall meet atthe bottom surface. The first sidewall meets the planar surface at thefirst angle along the length of the transition zone.

Example 17

The end effector of Example 16, wherein the second sidewall meets theplanar surface at the first angle along the length of the transitionzone.

Example 18

The end effector of Examples 11, 12, 13, 14, 15, 16, or 17, wherein thefirst angle is between 55 degrees and 80 degrees.

Example 19

The end effector of Examples 11, 12, 13, 14, 15, 16, 17, or 18, whereinthe profile curvatures are devoid of linear portions.

Example 20

The end effector of Examples 11, 12, 13, 14, 15, 16, 17, 18, or 19,wherein each profile curvature comprises a parabolic curvature.

Example 21

An end effector that comprises a staple cartridge that comprises astaple that comprises a first leg. The end effector further comprises ananvil that comprises a tissue compression surface, wherein a pluralityof pockets are defined in the tissue compression surface. The pluralityof pockets comprises a pocket that comprises a first cup configured toform the first leg. The first cup comprises a first lateral side, asecond lateral side, and a bottom intermediate the first lateral sideand the second lateral side. The bottom defines a depth relative to thetissue compression surface, wherein the depth varies longitudinallyalong the length of the bottom. The first cup further comprises a firstsidewall extending from the first lateral side to the bottom, whereinthe first sidewall defines a first entirely-curved surface, and a secondsidewall extending from the second lateral side to the bottom. Thesecond sidewall defines a second entirely-curved surface.

Example 22

The end effector of Example 21, wherein the first cup is devoid of flatsurfaces.

Example 23

The end effector of Examples 21 or 22, wherein the pocket furthercomprises a first beveled edge intermediate the tissue compressionsurface and the first lateral side and a second beveled edgeintermediate the tissue compression surface and the second lateral side.

Example 24

The end effector of Examples 21, 22, or 23, wherein the pocket furthercomprises a second cup. The staple further comprises a second legconfigured to form a second leg of the staple. The pocket is bilaterallysymmetric with respect to a longitudinal axis extending through thefirst cup and the second cup, wherein the pocket is bilaterallysymmetric with respect to a transverse axis oriented perpendicular tothe longitudinal axis and spaced equidistance from the first cup and thesecond cup.

Example 25

The end effector of Examples 21, 22, 23, or 24, wherein the first cupfurther comprises a plurality of boundary curves extending from thefirst lateral side to the second lateral side. Each boundary curvecomprises an inflection positioned along the bottom. The boundary curvestransect the tissue compression surface at a constant angle along thefirst lateral side and the second lateral side.

Example 26

The end effector of Example 25, wherein the boundary curves defineparabolic curves.

Example 27

An end effector that comprises a staple cartridge that comprises astaple that comprises a first leg. The end effector further comprises ananvil comprising a tissue compression surface, wherein a plurality ofpockets are defined in the tissue compression surface. The plurality ofpockets comprises a pocket that comprises a first cup configured to formthe first leg. The first cup comprises a first lateral side, a secondlateral side, and a bottom intermediate the first lateral side and thesecond lateral side. The bottom defines a depth relative to the tissuecompression surface, wherein the depth varies longitudinally along thelength of the bottom. The first cup further comprises a plurality ofparabolic boundary curves extending intermediate the first lateral sideand the second lateral side.

Example 28

The end effector of Example 27, wherein the first cup further comprisesan entry zone, an exit zone, a transition zone intermediate the entryzone and the exit zone, and a sidewall extending from the first lateralside toward the bottom. A tangent to the sidewall at the first lateralside is oriented at a constant angle in the entry zone, the exit zone,and the transition zone.

Example 29

The end effector of Examples 27 or 28, wherein the first cup defines anentirely-curved boundary surface.

Example 30

The end effector of Examples 27, 28, or 29, wherein the first cupfurther comprises a first sidewall extending from the first lateral sidetoward the bottom and a second sidewall extending from the secondlateral side toward the bottom, wherein each parabolic boundary curvecomprises a vertex positioned along the bottom.

Example 31

The end effector of Example 30, wherein the first sidewall defines afirst entirely-curved boundary surface. The second sidewall defines asecond entirely-curved boundary surface.

Example 32

The end effector of Examples 27, 28, 29, 30, or 31, wherein the pocketfurther comprises a first beveled edge intermediate the tissuecompression surface and the first lateral side and a second beveled edgeintermediate the tissue compression surface and the second lateral side.

Example 33

The end effector of Examples 27, 28, 29, 30, 31, or 32, wherein thestaple further comprises a second leg. The pocket further comprises asecond cup configured to form the second leg. The pocket is bilaterallysymmetric with respect to a longitudinal axis extending through thefirst cup and the second cup, wherein the pocket is bilaterallysymmetric with respect to a transverse axis oriented perpendicular tothe longitudinal axis and spaced equidistance from the first cup and thesecond cup.

Example 34

An end effector that comprises a staple cartridge that comprises astaple that comprises a first leg. The end effector further comprises ananvil that comprises a planar surface, wherein a plurality of pocketsare defined in the planar surface. The plurality of pockets comprises apocket that comprises a first cup configured to form the first leg. Thefirst cup defines an entirely-curved boundary surface comprising abottom, wherein the bottom defines a depth relative to the planarsurface. The depth varies longitudinally along the length of the bottom.

Example 35

The end effector of Example 34, wherein the staple further comprises asecond leg. The pocket further comprises a second cup configured to formthe second leg. The pocket is bilaterally symmetric with respect to alongitudinal axis extending through the first cup and the second cup,and wherein the pocket is bilaterally symmetric with respect to atransverse axis oriented perpendicular to the longitudinal axis andspaced equidistance from the first cup and the second cup.

Example 36

The end effector of Examples 34 or 35, wherein the first staple furthercomprises a second leg. The pocket further comprises a second cupconfigured to form the second leg. The second cup defines a secondentirely-curved boundary surface comprising a second bottom. The secondbottom defines a second depth relative to the planar surface. The seconddepth varies longitudinally along the length of the second bottom.

Example 37

The end effector of Examples 34, 35, or 36, wherein the first cupfurther comprises a first lateral side, a second lateral side, and aplurality of parabolic boundary curves extending intermediate the firstlateral side and the second lateral side.

Example 38

The end effector of Examples 34, 35, 36, or 37, wherein the first cupfurther comprises a first lateral side extending along an entry zone, anexit zone, and a transition zone intermediate the entry zone and theexit zone. The first cup further comprises a sidewall extending from thefirst lateral side toward the bottom, wherein a tangent to the sidewallat the first lateral side is oriented at a constant angle in the entryzone, the exit zone, and the transition zone.

Example 39

The end effector of Example 38, wherein a tangent to the sidewall at thefirst lateral side is oriented at an angle between 55 degrees and 80degrees.

Example 40

The end effector of Examples 34, 35, 36, 37, 38, or 39, wherein thepocket further comprises a first beveled edge extending along a firstlateral side of the pocket and a second beveled edge extending along asecond lateral side of the pocket.

Example 41

A surgical end effector that comprises an anvil movable between an openposition and a closed position. The anvil comprises a planar surface,wherein a plurality of forming pockets are defined in the planarsurface. The plurality of forming pockets comprises a first formingpocket that comprises a first depth and a second forming pocket thatcomprises a second depth, wherein the second depth is different than thefirst depth. The surgical end effector further comprises a staplecartridge that comprises a deck. The deck comprises a first portionaligned with the first pocket, a second portion aligned with the secondpocket, and a step intermediate the first portion and the secondportion. The staple cartridge further comprises a plurality of drivers.The plurality of drives comprises a first driver aligned with the firstpocket and movable a first distance between an unfired position and afired position and a second driver aligned with the second pocket andmovable a second distance between an unfired position and a firedposition. The second distance is different than the first distance. Thestaple cartridge further comprises a plurality of staples. The pluralityof staples comprises a first staple supported by the first driver,wherein the first staple is formed to a first formed height intermediatethe first driver and the first pocket. The plurality of staples furthercomprises a second staple supported by the second driver, wherein thesecond staple is formed to a second formed height intermediate thesecond driver and the second pocket. The first formed height is equal tothe second formed height.

Example 42

The surgical end effector of Example 41, wherein the difference betweenthe first distance and the second distance corresponds to the differencebetween the first depth and the second depth.

Example 43

The surgical end effector of Examples 41 or 42, wherein the first staplecomprises a first unformed height, wherein the second staple comprises asecond unformed height, and wherein the second unformed height is equalto the first unformed height.

Example 44

The surgical end effector of Examples 41 or 42, wherein the first staplecomprises a first unformed height, wherein the second staple comprises asecond unformed height, and wherein the second unformed height isdifferent than the first unformed height.

Example 45

The surgical end effector of Examples 41, 42, 43, or 44, wherein thestaple cartridge is replaceable.

Example 46

The surgical end effector of Examples 41, 42, 43, 44, or 45, wherein afirst tissue gap is defined between the first portion and the planarsurface, wherein a second tissue gap is defined between the secondportion and the planar surface, and wherein the first tissue gap is lessthan the second tissue gap.

Example 47

The surgical end effector of Examples 41, 42, 43, 44, 45, or 46, whereinthe first portion is laterally outboard of the second portion.

Example 48

A staple forming apparatus that comprises a plurality of first staples,wherein each first staple is supported by a first drive surface. Thestaple forming apparatus further comprises a plurality of secondstaples, wherein each second staple is supported by a second drivesurface. The staple forming apparatus further comprises a tissuecompression surface, wherein a plurality of forming pockets is definedin the tissue compression surface. The plurality of forming pocketscomprises a longitudinal row of first forming pockets each comprising afirst depth, wherein each first forming pocket is configured to form oneof the first staples to a first formed height within a first range offormed heights. The plurality of forming pockets further comprises alongitudinal row of second forming pockets each comprising a seconddepth. The second depth is different than the first depth, wherein eachsecond forming pocket is configured to form one of the second staples toa formed height within a second range of formed heights. The secondrange of formed heights is equal to the first range of formed heights.

Example 49

The staple forming apparatus of Example 48, wherein the first depth isdouble the second depth.

Example 50

The staple forming apparatus of Examples 48 or 49, wherein thelongitudinal row of first forming pockets is laterally outboard of thelongitudinal row of second forming pockets.

Example 51

The staple forming apparatus of Examples 48, 49, or 50, furthercomprising a staple cartridge that comprises a deck, wherein each firstdrive surface is configured to drive one of the first staples a firstoverdrive distance relative to the deck. The first overdrive distancecorresponds to the first depth, wherein each second drive surface isconfigured to drive one of the second staples a second overdrivedistance relative to the deck. The second overdrive distance correspondsto the second depth.

Example 52

The staple forming apparatus of Example 51, wherein the deck furthercomprises a stepped surface.

Example 53

The staple forming apparatus of Examples 48, 49, 50, 51, or 52, whereineach first drive surface is movable a first distance between an unfiredposition and a fired position. Each second drive surface is movable asecond distance between an unfired position and a fired position. Thesecond distance is different than the first distance.

Example 54

The staple forming apparatus of Example 53, wherein the differencebetween the first distance and the second distance corresponds to thedifference between the first depth and the second depth.

Example 55

A surgical end effector that comprises an anvil that comprises a tissuecompression surface, wherein a plurality of forming pockets is definedin the tissue compression surface. The plurality of forming pocketscomprises a first forming pocket comprising a first depth and a secondforming pocket comprising a second depth, wherein the second depth isdifferent than the first depth. The surgical end effector furthercomprises a staple cartridge. The staple cartridge comprises a pluralityof drivers comprising a first driver and a second driver. The staplecartridge further comprises a plurality of staples. The plurality ofstaples comprises a first staple comprising a first unformed height andsupported by the first driver, wherein the first staple is driven afirst distance into forming contact with the first pocket by the firstdriver and formed to a first formed height. The plurality of staplesfurther comprises a second staple comprising a second unformed heightand supported by the second driver, wherein the second staple is drivena second distance into forming contact with the second pocket by thesecond driver to a second formed height. The second distance isdifferent than the first distance. The second formed height issubstantially the same as the first formed height. The differencebetween the first distance and the second distance corresponds to thedifference between the first depth and the second depth.

Example 56

The surgical end effector of Example 55, wherein the tissue compressionsurface comprises a planar surface. The planar surface comprises a firstportion, wherein the first forming pocket is defined in the firstportion. The planar surface further comprises a second portion laterallyoutboard of the first portion, wherein the second forming pocket isdefined in the second portion.

Example 57

The surgical end effector of Example 56, wherein the surgical endeffector is movable between an open configuration and a closedconfiguration, and wherein a constant tissue gap is defined between thestaple cartridge and the first portion and the second portion of theplanar surface when the surgical end effector is in the closedconfiguration.

Example 58

The surgical end effector of Examples 56 or 57, wherein the surgical endeffector is movable between an open configuration and a closedconfiguration, wherein a first tissue gap is defined between the staplecartridge and the first portion, wherein a second tissue gap is definedbetween the staple cartridge and the second portion, and wherein thefirst tissue gap is different than the tissue gap.

Example 59

The surgical end effector of Examples 55, 56, 57, or 58, furthercomprising a sled configured to displace the first driver a first liftlength and configured to displace the second driver a second lift lengthduring a staple firing stroke. The first lift length is different thanthe second lift length.

Example 60

The surgical end effector of Examples 55, 56, 57, 58, or 59, wherein thestaple cartridge further comprises a deck. The first driver isconfigured to drive the first staple a first overdrive distance relativeto the deck, wherein the first overdrive distance corresponds to thefirst depth. The second driver is configured to drive the second staplea second overdrive distance relative to the deck, wherein the secondoverdrive distance corresponds to the second depth.

Example 61

The surgical end effector of Examples 55, 56, 57, 58, 59, or 60, whereinthe staples comprise a staple diameter, wherein the first depth is equalto the staple diameter, and wherein the second depth is equal to twicethe staple diameter.

Example 62

A surgical tool assembly that comprises an end effector that comprisesan elongate channel configured to receive a fastener cartridge. Theelongate channel comprises a brace. The surgical tool assembly furthercomprises a shaft that comprises an articulation drive assembly. Thearticulation drive assembly comprises an articulation link pivotablycoupled to the elongate channel. The articulation link comprises apocket configured to receive the brace when the end effector is in afully articulated configuration.

Example 63

The surgical tool assembly of Example 62, wherein the brace comprises anouter surface that comprises a plurality of first flat surfaces. Thepocket comprises an inner surface that comprises a plurality of secondflat surfaces. The second flat surfaces are complementary to the firstflat surfaces.

Example 64

The surgical tool assembly of Examples 62 or 63, wherein the shaftextends along a longitudinal axis. The articulation link is pivotablycoupled to the elongate channel at a pivot axis, wherein the pivot axisis laterally offset from the longitudinal axis.

Example 65

The surgical tool assembly of Examples 62, 63, or 64, wherein thearticulation drive assembly further comprises an articulation rodcoupled to the articulation link. The distal displacement of thearticulation rod is configured to pivot the end effector toward thefully articulated configuration.

Example 66

The surgical tool assembly of Example 65, wherein the articulation driveassembly further comprises an articulation lock configured toselectively prevent axial displacement of the articulation rod.

Example 67

The surgical tool assembly of Examples 62, 63, 64, 65, or 66, furthercomprising the fastener cartridge.

Example 68

A surgical tool assembly that comprises a shaft and an end effector thatcomprises a proximal portion, wherein the proximal portion comprises abrace. The surgical tool assembly further comprises an articulationassembly configured to articulate the end effector relative to the shaftbetween a first articulated configuration and a second articulatedconfiguration. The articulation assembly comprises an articulationdriver that comprises a recess. The recess is configured to receive thebrace when the end effector is in the first articulated configuration.

Example 69

The surgical tool assembly of Example 68, wherein the end effectorcomprises an elongate channel configured to receive a staple cartridge.The elongate channel comprises the brace.

Example 70

The surgical tool assembly of Example 69, further comprising the staplecartridge.

Example 71

The surgical tool assembly of Examples 69 or 70, wherein the bracecomprises a post protruding from the elongate channel.

Example 72

The surgical tool assembly of Example 71, wherein the post comprises anouter surface that comprises a plurality of flat surfaces.

Example 73

The surgical tool assembly of Example 72, wherein the recess comprisesan inner surface that comprises a plurality of second flat surfaces. Theplurality of second flat surfaces are complementary to the flat surfacesof the post.

Example 74

The surgical tool assembly of Examples 69, 70, 71, 72, or 73, whereinthe articulation driver comprises an articulation link. The articulationlink comprises a proximal end and a distal end. The proximal end iscoupled to an articulation rod. The distal end is pivotably coupled tothe elongate channel.

Example 75

The surgical tool assembly of Example 74, wherein the shaft extendsalong a longitudinal axis. The distal end of the articulation link islaterally offset from the longitudinal axis.

Example 76

The surgical tool assembly of Examples 68, 69, 70, 71, 72, 73, 74, or75, further comprising a second brace. The articulation driver comprisesa second recess configured to receive the second brace when the endeffector is in the second articulated configuration.

Example 77

The surgical tool assembly of Examples 68, 69, 70, 71, 72, 73, 74, 75,or 76, wherein the second articulated configuration is at least 120degrees offset from the first articulated configuration.

Example 78

A surgical tool assembly that comprises a shaft and an end effector. Theend effector comprises an elongate channel configured to receive afastener cartridge. The surgical tool assembly further comprises anarticulation assembly intermediate the shaft and the end effector. Thearticulation assembly is configured to articulate the end effectorrelative to the shaft. The articulation assembly comprises anarticulation link pivotably coupled to the elongate channel. Thesurgical tool assembly further comprises means for countering bucklingof the articulation link when the articulation link is compressed.

Example 79

The surgical tool assembly of Example 78, further comprising thefastener cartridge.

Example 80

A surgical tool assembly that comprises a shaft and an end effector. Theend effector comprises an elongate channel configured to receive afastener cartridge. The surgical tool assembly further comprises anarticulation assembly configured to articulate the end effector relativeto the shaft. The articulation assembly comprises an articulation driverpivotably coupled to the end effector. The surgical tool assemblyfurther comprises means for bracing the articulation driver when the endeffector is in a fully-articulated configuration.

Example 81

The surgical tool assembly of Example 80, further comprising thefastener cartridge.

Example 82

A surgical tool assembly that comprises a shaft and an end effector. Theend effector comprises a proximal end and a distal end. The surgicaltool assembly further comprises an articulation joint rotatablyconnecting the proximal end of the end effector to the shaft. Thesurgical tool assembly further comprises an articulation assemblyconfigured to articulate the end effector relative to the shaft betweena first articulated configuration and a second articulatedconfiguration. The articulation assembly comprises a longitudinalarticulation driver movable proximally and distally. The articulationassembly further comprises a link connecting the longitudinalarticulation driver to the end effector. The articulation assemblyfurther comprises a feature that does not interfere with the proximaland distal movement of the articulation driver to articulate the endeffector but resists the counter-rotation of the end effector to preventthe back-driving of the articulation driver.

Many of the surgical instrument systems described herein are motivatedby an electric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In various instances,the surgical instrument systems described herein can be motivated by amanually-operated trigger, for example. In certain instances, the motorsdisclosed herein may comprise a portion or portions of a roboticallycontrolled system. Moreover, any of the end effectors and/or toolassemblies disclosed herein can be utilized with a robotic surgicalinstrument system. U.S. patent application Ser. No. 13/118,241, entitledSURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, disclosesseveral examples of a robotic surgical instrument system in greaterdetail.

The surgical instrument systems described herein have been described inconnection with the deployment and deformation of staples; however, theembodiments described herein are not so limited. Various embodiments areenvisioned which deploy fasteners other than staples, such as clamps ortacks, for example. Moreover, various embodiments are envisioned whichutilize any suitable means for sealing tissue. For instance, an endeffector in accordance with various embodiments can comprise electrodesconfigured to heat and seal the tissue. Also, for instance, an endeffector in accordance with certain embodiments can apply vibrationalenergy to seal the tissue.

The entire disclosures of:

-   -   U.S. Pat. No. 5,403,312, entitled ELECTROSURGICAL HEMOSTATIC        DEVICE, which issued on Apr. 4, 1995;    -   U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING INSTRUMENT        HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, which        issued on Feb. 21, 2006;    -   U.S. Pat. No. 7,422,139, entitled MOTOR-DRIVEN SURGICAL CUTTING        AND FASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK, which        issued on Sep. 9, 2008;    -   U.S. Pat. No. 7,464,849, entitled ELECTRO-MECHANICAL SURGICAL        INSTRUMENT WITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS,        which issued on Dec. 16, 2008;    -   U.S. Pat. No. 7,670,334, entitled SURGICAL INSTRUMENT HAVING AN        ARTICULATING END EFFECTOR, which issued on Mar. 2, 2010;    -   U.S. Pat. No. 7,753,245, entitled SURGICAL STAPLING INSTRUMENTS,        which issued on Jul. 13, 2010;    -   U.S. Pat. No. 8,393,514, entitled SELECTIVELY ORIENTABLE        IMPLANTABLE FASTENER CARTRIDGE, which issued on Mar. 12, 2013;    -   U.S. patent application Ser. No. 11/343,803, entitled SURGICAL        INSTRUMENT HAVING RECORDING CAPABILITIES; now U.S. Pat. No.        7,845,537;    -   U.S. patent application Ser. No. 12/031,573, entitled SURGICAL        CUTTING AND FASTENING INSTRUMENT HAVING RF ELECTRODES, filed        Feb. 14, 2008;    -   U.S. patent application Ser. No. 12/031,873, entitled END        EFFECTORS FOR A SURGICAL CUTTING AND STAPLING INSTRUMENT, filed        Feb. 15, 2008, now U.S. Pat. No. 7,980,443;    -   U.S. patent application Ser. No. 12/235,782, entitled        MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT, now U.S. Pat. No.        8,210,411;    -   U.S. patent application Ser. No. 12/249,117, entitled POWERED        SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY        RETRACTABLE FIRING SYSTEM, now U.S. Pat. No. 8,608,045;    -   U.S. patent application Ser. No. 12/647,100, entitled        MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR        DIRECTIONAL CONTROL ASSEMBLY, filed Dec. 24, 2009; now U.S. Pat.        No. 8,220,688;    -   U.S. patent application Ser. No. 12/893,461, entitled STAPLE        CARTRIDGE, filed Sep. 29, 2012, now U.S. Pat. No. 8,733,613;    -   U.S. patent application Ser. No. 13/036,647, entitled SURGICAL        STAPLING INSTRUMENT, filed Feb. 28, 2011, now U.S. Pat. No.        8,561,870;    -   U.S. patent application Ser. No. 13/118,241, entitled SURGICAL        STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT        ARRANGEMENTS, now U.S. Pat. No. 9,072,535;    -   U.S. patent application Ser. No. 13/524,049, entitled        ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE,        filed on Jun. 15, 2012; now U.S. Pat. No. 9,101,358;    -   U.S. patent application Ser. No. 13/800,025, entitled STAPLE        CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13,        2013, now U.S. Pat. No. 9,345,481;    -   U.S. patent application Ser. No. 13/800,067, entitled STAPLE        CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13,        2013, now U.S. Patent Application Publication No. 2014/0263552;    -   U.S. Patent Application Publication No. 2007/0175955, entitled        SURGICAL CUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER        LOCKING MECHANISM, filed Jan. 31, 2006; and    -   U.S. Patent Application Publication No. 2010/0264194, entitled        SURGICAL STAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR,        filed Apr. 22, 2010, now U.S. Pat. No. 8,308,040, are hereby        incorporated by reference herein.

Although various devices have been described herein in connection withcertain embodiments, modifications and variations to those embodimentsmay be implemented. Particular features, structures, or characteristicsmay be combined in any suitable manner in one or more embodiments. Thus,the particular features, structures, or characteristics illustrated ordescribed in connection with one embodiment may be combined in whole orin part, with the features, structures or characteristics of one oremore other embodiments without limitation. Also, where materials aredisclosed for certain components, other materials may be used.Furthermore, according to various embodiments, a single component may bereplaced by multiple components, and multiple components may be replacedby a single component, to perform a given function or functions. Theforegoing description and following claims are intended to cover allsuch modification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, a device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the stepsincluding, but not limited to, the disassembly of the device, followedby cleaning or replacement of particular pieces of the device, andsubsequent reassembly of the device. In particular, a reconditioningfacility and/or surgical team can disassemble a device and, aftercleaning and/or replacing particular parts of the device, the device canbe reassembled for subsequent use. Those skilled in the art willappreciate that reconditioning of a device can utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

The devices disclosed herein may be processed before surgery. First, anew or used instrument may be obtained and, when necessary, cleaned. Theinstrument may then be sterilized. In one sterilization technique, theinstrument is placed in a closed and sealed container, such as a plasticor TYVEK bag. The container and instrument may then be placed in a fieldof radiation that can penetrate the container, such as gamma radiation,x-rays, and/or high-energy electrons. The radiation may kill bacteria onthe instrument and in the container. The sterilized instrument may thenbe stored in the sterile container. The sealed container may keep theinstrument sterile until it is opened in a medical facility. A devicemay also be sterilized using any other technique known in the art,including but not limited to beta radiation, gamma radiation, ethyleneoxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdo not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

What is claimed is:
 1. A surgical end effector, comprising: an anvil movable between an open position and a closed position, wherein said anvil comprises a non-stepped planar surface, wherein a plurality of forming pockets are defined in said non-stepped planar surface, and wherein said plurality of forming pockets comprise: a first forming pocket comprising a first depth; and a second forming pocket comprising a second depth, wherein said second depth is different than said first depth; and a staple cartridge, comprising: a deck, comprising: a first tissue-contacting surface aligned with said first pocket; a second tissue-contacting surface aligned with said second pocket, wherein a first tissue gap is defined between said first tissue-contacting surface and said non-stepped planar surface, wherein a second tissue gap is defined between said second tissue-contacting surface and said non-stepped planar surface, and wherein said second tissue gap is less than said first tissue gap; a step intermediate said first tissue-contacting surface and said second tissue-contacting surface, wherein said second tissue-contacting surface is positioned above said first tissue-contacting surface; a longitudinal slot, wherein said first tissue-contacting surface and said second tissue-contacting surface are positioned on one side of said longitudinal slot, and wherein said second tissue-contacting surface is positioned further away from said longitudinal slot than said first tissue-contacting surface; and a plurality of drivers, comprising: a first driver aligned with said first pocket and movable a first distance between an unfired position and a fired position, wherein said first driver comprises a first drive surface; and a second driver aligned with said second pocket and movable a second distance between an unfired position and a fired position, wherein said second distance is different than said first distance, and wherein said second driver comprises a second drive surface; and a plurality of staples, comprising: a first staple supported on said first drive surface of said first driver, wherein said first drive surface is positioned above said first tissue-contacting surface of said deck when said first driver is in said fired position, and wherein said first staple is formed to a first formed height intermediate said first driver and said first pocket; and a second staple supported on said second drive surface of said second driver, wherein said second drive surface is positioned above said second tissue-contacting surface of said deck when said second driver is in said fired position, and wherein said second staple is formed to a second formed height intermediate said second driver and said second pocket, and wherein said first formed height is equal to said second formed height.
 2. The surgical end effector of claim 1, wherein the difference between said first distance and said second distance corresponds to the difference between said first depth and said second depth.
 3. The surgical end effector of claim 1, wherein said first staple comprises a first unformed height, wherein said second staple comprises a second unformed height, and wherein said second unformed height is equal to said first unformed height.
 4. The surgical end effector of claim 1, wherein said first staple comprises a first unformed height, wherein said second staple comprises a second unformed height, and wherein said second unformed height is different than said first unformed height.
 5. The surgical end effector of claim 1, wherein said staple cartridge is replaceable.
 6. The surgical end effector of claim 1, further comprising: a plurality of staple cavities defined in said staple cartridge, wherein each staple cavity defines an opening in said deck; and a plurality of discrete staple cavity extenders at least partially surrounding each opening in said deck.
 7. A staple forming apparatus, comprising: a plurality of first staples, wherein each said first staple is supported by a first drive surface; a plurality of second staples, wherein each said second staple is supported by a second drive surface; a non-stepped tissue compression surface, wherein a plurality of forming pockets are defined in said non-stepped tissue compression surface, and wherein said plurality of forming pockets comprise: a longitudinal row of first forming pockets each comprising a first depth, wherein each said first forming pocket is configured to form a said first staple to a first formed height within a first range of formed heights; and a longitudinal row of second forming pockets each comprising a second depth, wherein said second depth is different than said first depth, wherein each said second forming pocket is configured to form a said second staple to a second formed height within a second range of formed heights, and wherein said second range of formed heights is equal to said first range of formed heights; and a staple cartridge comprising a deck and a longitudinal slot, wherein said deck comprises a tissue-contacting surface comprising a first deck surface and a second deck surface positioned on one side of said longitudinal slot, wherein said second deck surface is positioned above said first deck surface, wherein said second deck surface is positioned further away from said longitudinal slot than said first deck surface, wherein each said first drive surface is configured to drive a said first staple a first overdrive distance above said first deck surface, wherein each said second drive surface is configured to drive a said second staple a second overdrive distance above said second deck surface, wherein a first tissue gap is defined between said first deck surface and said non-stepped tissue compression surface, wherein a second tissue gap is defined between said second deck surface and said non-stepped tissue compression surface, and wherein said second tissue gap is less than said first tissue gap.
 8. The staple forming apparatus of claim 7, wherein said first depth is double said second depth.
 9. The staple forming apparatus of claim 8, wherein said longitudinal row of first forming pockets and said longitudinal row of second forming pockets are positioned on one side of said longitudinal slot, and wherein said longitudinal row of first forming pockets is positioned further away from said longitudinal slot than said longitudinal row of second forming pockets.
 10. The staple forming apparatus of claim 7, wherein said first overdrive distance corresponds to said first depth, and wherein said second overdrive distance corresponds to said second depth.
 11. The staple forming apparatus of claim 7, wherein each said first drive surface is movable a first distance between an unfired position and a fired position, wherein each said second drive surface is movable a second distance between an unfired position and a fired position, and wherein said second distance is different than said first distance.
 12. The staple forming apparatus of claim 11, wherein the difference between said first distance and said second distance corresponds to the difference between said first depth and said second depth.
 13. The staple forming apparatus of claim 7, further comprising: a plurality of staple cavities defined in said staple cartridge, wherein each staple cavity defines an opening in said deck; and a plurality of discrete staple cavity extenders at least partially surrounding each opening in said deck.
 14. A surgical end effector, comprising: an anvil comprising a non-stepped tissue compression surface, wherein a plurality of forming pockets are defined in said tissue compression surface, and wherein said plurality of forming pockets comprise: a first forming pocket comprising a first depth; and a second forming pocket comprising a second depth, wherein said second depth is different than said first depth; and a staple cartridge, comprising: a longitudinal slot; a deck comprising a tissue-contacting surface, wherein said tissue contacting surface comprises a first planar surface and a second planar surface positioned on one side of said longitudinal slot, wherein said second planar surface is positioned above said first planar surface, wherein a first tissue gap is defined between said first planar surface and said non-stepped tissue compression surface when said surgical end effector is in a closed configuration, wherein a second tissue gap is defined between said second planar surface and said non-stepped tissue compression surface when said surgical end effector is in said closed configuration, and wherein said second tissue gap is less than said first tissue gap; a plurality of drivers comprising a first driver and a second driver; and a plurality of staples, comprising: a first staple comprising a first unformed height and supported on a first drive surface of said first driver, wherein said first staple is driven a first distance into forming contact with said first pocket by said first driver and formed to a first formed height, and wherein said first drive surface is positioned above said tissue-contacting surface of said deck when said first staple is formed to said first formed height; and a second staple comprising a second unformed height and supported on a second drive surface of said second driver, wherein said second staple is driven a second distance into forming contact with said second pocket by said second driver to a second formed height, wherein said second distance is different than said first distance, wherein said second drive surface is positioned above said tissue-contacting surface of said deck when said second staple is formed to said first formed height, wherein said second formed height is substantially the same as said first formed height, and wherein the difference between said first distance and said second distance corresponds to the difference between said first depth and said second depth.
 15. The surgical end effector of claim 14, further comprising a sled configured to displace said first driver a first lift length and configured to displace said second driver a second lift length during a staple firing stroke, wherein said first lift length is different than said second lift length.
 16. The surgical end effector of claim 14, wherein said first driver is configured to drive said first staple a first overdrive distance relative to said tissue-contacting surface of said deck, wherein said first overdrive distance corresponds to said first depth, wherein said second driver is configured to drive said second staple a second overdrive distance relative to said tissue-contacting surface of said deck, and wherein said second overdrive distance corresponds to said second depth.
 17. The surgical end effector of claim 14, wherein said staples comprise a staple diameter, wherein said first depth is equal to said staple diameter, and wherein said second depth is equal to twice said staple diameter.
 18. The surgical end effector of claim 14, further comprising: a plurality of staple cavities defined in said staple cartridge, wherein each staple cavity defines an opening in said deck; and a plurality of discrete staple cavity extenders at least partially surrounding each opening in said deck. 